Documenti di Didattica
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^
Boot Diagnostics Menu
143
Printer Information Menu
You can view various printer statistics, such as hours of usage, and refer to
these figures for preventive maintenance purposes. Printer statistics
accumulate continuously; they do not reset when you power off the printer.
All of the printer statistics are set to zero at the factory after burn-in testing.
Figure 20. Printer Information Menu
Installed Memory
Displays the amount of RAM in Megabytes installed in the printer.
Power-on Time
The cumulative time in hours that the printer has been powered on. The range
is 0 to 30,000 hours.
Printing Time
The cumulative time in hours that the printer has actually been printing. The
range is 0 to 30,000 hours.
Print Strokes
The cumulative number of back-and-forth shuttle strokes the printer has made
during normal operation. The range is 0 to 4,000,000,000 shuttle strokes.
11 Inch Pages
The cumulative number of pages the printer has printed. The range is 0 to
363,000,000 pages.
Printer
Information
Installed Memory Power On Time Printing Time 11 Inch Pages
To view options, press:
Scroll Scroll Enter
Start
Return
To select an option, press:
Enter
To exit the configuration menus and
return to READY, press:
* = Factory Default
144
Chapter 5 Printer Information Menu
Displaying Printer Information
You obtain printer information by using the configuration menus, as follows:
Step Press Displayed Result Notes
1. Install the ribbon, load paper, and power on the printer.
2.
NOT READY Puts printer in NOT
READY mode.
3.
OPERATOR MENU
UNLOCKED
Unlocking ENTER key
gives you access to the
configuration menus.
4.
OPERATOR MENU
PRINTER CONTROL
First of series of
configuration menus.
5.
OPERATOR MENU
PRINTER INFORMATION
Advances to the Printer
Information menu.
6.
PRINTER INFORMATION
INSTALLED MEMORY
Advances to the first of
the Printer Information
menus.
7.
PRINTER INFORMATION
[MENU NAME]
Stop when the menu you
want is displayed.
8.
[MENU NAME]
[STATISTICS OR INFO]
Your selection displays
the information.
9.
NOT READY Returns printer to NOT
READY mode.
Stop
+ Scroll Scroll
Menu
UNTIL
Scroll
Enter
Scroll
Enter
Stop
Soft Reset
145
Soft vs. Hard Reset
Resetting the printer returns it to a previous configuration. There are two kinds
of reset.
Soft Reset
A soft(ware) reset clears printer memory then loads the power-up
configuration into memory. (The procedure for saving configurations is
described in the Setup Guide.) It is called a soft reset because no hardware is
tested. All diagnostic and initialization tests are bypassed and memory is
simply refreshed with the power-up printer configuration.
Put the printer in the NOT READY state to do a soft reset:
1. Press the Stop key to put the printer in the NOT READY state.
2. Press the Stop + Enter keys.
The LCD displays STANDBY..., SOFT RESET while the printer loads
the power-up configuration.
Hard Reset (Cycle Power)
A hard(ware) reset is a power shutdown and restart that runs all initialization
and diagnostic routines. This is also called cycling power.
1. Set the printer power switch to O (off).
2. Wait 15 seconds.
3. Set the printer power switch to 1 (on).
NOTE: A hard printer reset causes the +48V power supply (fans, motors,
etc.) to shut down in 1 to 5 seconds, depending on the amount of
memory installed on the controller board.
146
Chapter 5 The Power On Sequence
The Power On Sequence
This section describes the normal sequence of events from the time the
power switch is set to 1 until READY (or NOT READY, if so configured by the
user) appears on the LCD.
Use this sequence as a reference baseline to help you isolate problems that
occur before the printer completes its boot and initialization routines.
The power on sequence consists of two sets of routines:
1. CMX controller board handshake sequences (DC hardware initialization)
2. DC software initialization and power up
The routines are listed below, in order of occurrence.
CMX Controller Board Handshake Sequences
The first power-up routines are the handshaking sequences which sample
and test the condition of the CMX controller board. The sequences occur as
follows:
Processor Alive The green LED marked CR1 on the CMX controller
board is turned on to indicate that the processor received a valid reset
vector and the first instructions to the processor are correct. This LED is
used to report all DC errors and states.
Test VX Data Bus A walking zero and one test verifies that all 32 data
lines from the VX bus to the processor are connected. If a bad line is
detected, a 4-1-1-XX blink code is sent to the LED on the CMX controller,
where XX is the data line plus 1. (For example, a bad data line 8 would
blink as 4-1-1-9.)
Initialize VX ASIC The boot code detects the processor type and sets
up the internal registers of the VX ASIC.
Initialize Debug Serial Port The boot code checks the validity of the
debug serial parameters in NVRAM; if they are valid, it sets the baud rate,
data type, and which messages should be sent out the debug port. If the
values in NVRAM are not valid, boot code initializes NVRAM to 9600
baud, 8 data bits, one stop, bit, no parity bit, and standard messages.
Turn On Instruction Cache The instruction cache is turned on to help
speed up memory tests and the entire boot process.
Enable DRAM Controller A DRAM controller is built into the VX ASIC.
DRAM must be refreshed a few times to operate correctly. To speed the
boot process, the refresh rate is temporarily increased. The message
TESTING HARDWARE PLEASE WAIT is sent to the LCD, during which
time the refreshes run and finish. At this point, the fans start. After
sending the message, the refresh rate is set to the proper rate and DRAM
is ready to be tested.
Test I/O Clock The VX ASIC has two clocks for internal timing, a
processor clock and an I/O clock. The processor clock cannot be checked
because the processor will not run without it, but the I/O clock can be
checked. The I/O clock is used for sending data to the operator panel and
to get the time for DRAM refreshes. If the boot code detects a problem
CMX Controller Board Handshake Sequences
147
with the I/O clock, the error blink code 4-3-4 is sent to the diagnostic LED
on the CMX board.
Read Operator Panel Keys The operator panel keys are read to
determine if the user is requesting that the printer be placed in download
mode, diagnostic mode, or debug SIMM disabled. If Cancel and Start are
pressed during start-up, the printer is placed in download mode. If Eject/
Restore and Stop are pressed during start-up, the printer is placed in
diagnostic mode. If any other combination of keys are pressed, the debug
SIMM is disabled. Key states are put in an internal register in the VX
ASIC.
Detect DRAM The VX ASIC supports up to four banks of DRAM
totalling up to 32 Megabytes. Boot code detects how much DRAM is
located in each bank, and relocates the banks to create one contiguous
block of DRAM. The size and location of each bank is then displayed on
the debug terminal through the debug serial port.
Test DRAM DRAM is tested by writing a pseudorandom number
sequence to all the DRAM, then reading the pattern back to verify it
against what was originally written. If an error is detected, the message
ERROR: DRAM AT ADDRESS XXXXXXXX is displayed on the LCD.
When finished, the DRAM test sets all memory to zero.
Inform the EC Processor The first 8 Kilobytes of DRAM are reserved
for the EC processor, which must be notified when DRAM is ready to be
used. This is done by putting the message DCS1 in the ECDC
communications register in the VX ASIC.
Detect Ethernet Adapter An Ethernet adapter must be detected early
in the power up sequence so the printer can tell the adapter it has been
detected and continue with its own power up sequence. An Ethernet
adapter takes a long time to complete its internal diagnostic tests, so the
boot code allows the adapter to power up in parallel with the printer to
reduce its effect on overall boot time.
Load Boot Messages The boot code scans flash memory for OEM
boot messages and loads them into DRAM. The manufacturers boot
code is the same for all OEMs, and contains a set of default messages.
Boot messages for specific OEMs are stored in the DC code, not the boot
code.
Load Boot Code into DRAM Flash memory cannot be accessed
while flash is being detected, cleared, or programmed. This prevents boot
code from running in flash because the opcodes cannot be fetched. This
is solved by copying the program into DRAM and executing the program
out of DRAM. The boot code is positionindependent in order for the
program to operate at a different address. The interrupt vector table is
also move to DRAM and the vectors are changed to reflect the new
address.
Detect Flash The boot code supports many different kinds of flash
memory, permitting any mixture of flash in the four memory banks. The
only requirement is that flash must exist in bank 0 and have boot code
programmed on it. The boot code displays flash configuration,
manufacturers part number, size, and start address out the debug serial
port.
148
Chapter 5 The Power On Sequence
Display VX Registers The boot code displays the values of the VX
registers out of the debug serial port.
Check for Pedestal Boot code uses the operator panel to determine if
the printer is a pedestal or floor cabinet model. Boot code needs to know
the difference so the exhaust fan fault can be disabled on a pedestal
model. FAN DISABLED is printed out at the debug serial port of a
pedestal model.
Check for Download Mode Boot code checks whether the Cancel
and Start keys were pressed at power up. If so, the printer enters
download mode. If not, the printer continues the boot routines.
Check for Diagnostics Mode Boot code checks whether the Eject/
Restore and Stop keys were pressed at power up. If so, the printer
enters the Boot Diagnostics menu. If not, the printer continues the boot
routines.
Check for Remote Download Mode Boot code checks if the user
remotely requested the printer to enter download mode. If so, the printer
enters download mode. If not, the printer continues boot routines.
Check for Flash Optimize Boot code checks if the user requested the
flash file system to be optimized at power up. If so, flash memory is
optimized at this time. If not, the printer continues boot routines.
Check EC Program The EC calculates a checksum of the program
stored in its flash memory. If there is problem with its program, the EC
puts the message nopg in the ECDC communications register. If the
boot code detects this message, it displays ERROR: EC PROGRAM
NOT VALID on the LCD. If the EC processor does not respond within
three seconds, the boot code sends EC STOPPED AT STATE XXXX to
the LCD, where XXXX is one of these states:
State Description
0000 Power up
0001 Enter checksum calculation
0002 Enter copy download code from FLASH into shared DRAM
0003 Enter programming FLASH mode
0004 Erase EC FLASH
0005 Program FLASH
0006 Finish programming FLASH
0007 Enter initialization of EC serial debug
0008 Enter EC firmware task initializations
0009 Enter power up coil diagnostic
000A Start running normal EC firmware
CMX Controller Board Handshake Sequences
149
Check Security PAL and NVRAM The chip select for NVRAM comes
from the security PAL. If the PAL is not installed, NVRAM cannot be
accessed, so the PAL is tested before NVRAM. If the security PAL is not
detected, boot codes displays ERROR: SECURITY PAL NOT
DETECTED. If a security PAL is detected, boot code checks for the
presence of NVRAM. If NVRAM is not found, boot code displays
ERROR: NVRAM FAILURE.
Test for Powerup File Boot code checks for a DC executable file
called powerup.sbr. If found, it executes the file, then returns to boot
routines. If the file is not found, boot routines are resumed. If any key was
held down during power up, boot code does not look for the powerup file
and continues the boot sequence.
Automatic EC Update Boot code checks whether the automatic EC
update feature is enabled by the DC program. If so, it looks for a copy of
the EC program in the Flash File System. If it has a copy, it compares the
program in EC flash to the program in the Flash File System, and updates
the EC program if they are different. If the automatic EC update was not
enabled, or if any key was held down during power up, automatic EC
update is skipped and the boot sequence continues normally.
Debug SIMM The debug SIMM contains fast static RAM that
automatically replaces the flash memory. Boot code checks for the debug
SIMM and, if found, copies the contents of flash memory into the SIMM,
then remaps the address of the SIMM to the location of flash. This allows
breakpoints and singlestepping from the MTOS** debugger. When the
debug SIMM is found, boot code displays DEBUG SIMM ACTIVATED
on the panel and out the debug port.
Verify DC Program Boot code calculates a checksum at every power
up to verify that the program has not been corrupted. If the checksum
does not match, boot code displays ERROR: DC PROGRAM NOT
VALID.
Check Security The security check verifies that security PAL supports
the software that is loaded in flash memory. If the PAL does not support
the software, boot code displays SECURITY CODE VIOLATION.
Check Required DRAM Boot code checks whether the amount of
DRAM required to run the DC program is larger than the amount of
DRAM in the printer. If so, it displays the message ERROR: PROGRAM
NEEDS MORE DRAM.
Tell EC Processor to Finish Booting Boot code informs the EC
processor that everything is okay and can finish booting up.
Diagnostics Passed If all tests pass, boot code displays
P05 DIAGNOSTIC TEST PASSED. At this point, the ribbon motors
engage. Boot code then jumps to the start address of the DC software.
Display DC Program Information Boot code sends the following
information out the debug port: the compile time, date, and the address it
will jump to to start the DC program.
Waiting Ethernet If boot code earlier detected an Ethernet adapter, it
places the message WAITING FOR THE ETHERNET ADAPTER on the
LCD so the user will not think the printer has crashed.
150
Chapter 5 The Power On Sequence
Jump Back into Flash and Clear DRAM Boot code jumps back into
flash memory, then clears the DRAM that held the boot code.
Jump to MTOS Jump to start initialization of the MTOS (Multi-Tasking
Operating System).
DC Software Initialization And Power Up
The final part of the power up sequence is initialization and startup of the DC
software, which occurs in the following order:
Clear Uninitialized RAM Variables
Set Initialized RAM Variables
Configure RAM (allocated based upon amount in the printer)
Jump to MTOS (Multi-Tasking Operating System)
Initialize the Processor (cache, vector table, etc.)
Partition RAM for Tasks
Allocate Peripheral Interfaces (console driver, etc.)
Start Main Task (supervisor)
Verify and Initialize NVRAM (statistics are cleared if NVRAM is not valid)
Initialize Libraries (fault, system, emulation)
Load Front Panel Menus from ROM
Initialize these tasks, then start them after all have initialized:
Print Engine Driver Task
CT Driver Task (sends 8344 code to the CT expansion board)
Serial Driver Task
Parallel Driver Task
CT Emulation Task
IGP Task (PGL or VGL)
Base Emulation Task:
Initialize Fonts
Initialize Graphics Library
Complete Emulation Library Initialization
Wait for all emulation tasks to initialize
Front Panel Task
Display READY on operator panel
151
6 Adjustment Procedures
Introduction
The IBM 6400 series printer is a durable, low-maintenance machine, but
some components and systems require occasional adjustment.
Usually, you will be referred to this chapter by a troubleshooting procedure, or
as part of a removal/installation procedure.
List Of Adjustments
Preparing the Printer for Maintenance ............................................ page 152
Returning the Printer to Normal Operation...................................... page 153
Belt, Paper Feed Timing, Adjustment ............................................. page 154
Belt, Platen Open, Adjustment ........................................................ page 156
Paper Drive Motor Pulley Alignment ............................................... page 158
Paper Scale Alignment.................................................................... page 160
Platen Gap Adjustment ................................................................... page 162
Platen Open Motor Pulley Alignment .............................................. page 164
Ribbon Guide Alignment ................................................................. page 166
Splined Shaft Skew Adjustment ...................................................... page 168
Adjusting the End of Forms Distance.............................................. page 169
Hammer Phasing Adjustment ......................................................... page 173
Downloading 6400 Microcode from the World Wide Web............... page 175
Loading Flash Memory.................................................................... page 176
Coil Temperature Adjustment ......................................................... page 181
Set Shuttle Speed ........................................................................... page 182
Ethernet Initialization....................................................................... page 183
152
Chapter 6 Preparing The Printer For Maintenance
Preparing The Printer For Maintenance
To prepare the printer for maintenance, always do the following steps before
you do any maintenance procedure:
1. Power off the printer.
2. Unplug the printer power cord from the AC power source.
3. Disconnect the host data cable from the printer interface.
4. Open the printer cover.
5. Unload paper.
6. Remove the ribbon.
7. Read the entire adjustment procedure before you begin working on the
printer.
8. Gather the necessary parts before you begin working on the printer.
<3> Hazardous voltages are present in the printer with the
power cord connected to the power source. Switch off
printer power and unplug the printer power cord before
proceeding.
DANGER
List Of Adjustments
153
Returning The Printer To Normal Operation
When you are finished servicing the printer, restore it to operation by following
these steps:
1. Connect the host data cable to the printer interface.
2. Install the ribbon.
3. Load paper.
4. Plug the AC power cord into the power source.
5. Close the cabinet doors.
6. Power on the printer.
7. Set the top-of-form. (Refer to the Operators Guide.)
8. Select the emulation. (Refer to the Operators Guide.)
9. Test printer operation by selecting and running one of the operator print
tests.
10. Close the printer cover.
154
Chapter 6 Belt, Paper Feed Timing, Adjustment
Belt, Paper Feed Timing, Adjustment
To make this adjustment, follow these steps:
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Cabinet Model: Loosen four screws and remove the barrier shield. (See
page 258, Figure 44, items 3 and 4.)
Pedestal Model: Remove the four screws securing the paper guide and
barrier shield. Remove the paper guide and barrier shield. (See page 260,
Figure 45, items 3, 4, and 5.)
4. Remove the timing belt cover (1) by squeezing the front and back to
release the plastic tabs from the slots in the side plate.
5. Loosen (do not remove) the motor mount bolts (2).
6. Using the straight end of a force gauge, apply 15 pounds (66.7 N) of
pressure to the paper feed drive motor (3) near the mounting base of the
motor. Use the splined shaft (4) to steady the gauge.
7. Reduce tension to 12 pounds (53.4 N) and torque the paper feed motor
mount bolts (2) to 18 2 inch-pounds (2.03 0.23 Nm).
8. Snap the timing belt cover (1) into the slots in the side plate.
9. Cabinet Model: Install the barrier shield and tighten the four screws. (See
page 258, Figure 44, items 3 and 4.)
Pedestal Model: Install the paper guide and barrier shield and tighten the
four screws. (See page 260, Figure 45, items 3, 4, and 5.)
10. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
11. Return the printer to normal operation (page 153).
List Of Adjustments
155
Legend:
1) Timing Belt Shield
2) Motor Mount Bolt (2)
3) Paper Feed Drive Motor
4) Splined Shaft
Figure 21. Paper Feed Timing Belt Adjustment
Direction of Force
1
2
3
4
2
$
$
156
Chapter 6 Belt, Platen Open, Adjustment
Belt, Platen Open, Adjustment
To make this adjustment, follow these steps:
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Remove the platen open belt cover (1) by squeezing the top and bottom
to release the plastic tabs from the slots in the side plate.
4. Loosen the motor mount screws (2).
5. Close the forms thickness lever all the way.
ATTENTION
Too much tension on the platen open belt can cause the platen gap to
change, which can lead to premature wear of the platen, damaged
hammer tips, and poor print quality.
6. Using a force gauge, apply 10 1 pounds (44.48 4.45 N) of tension to
the shank of the platen drive pulley (3), pushing away from the large
platen pulley.
7. Reduce tension to 5 1 pounds (22.24 4.45 N) and tighten the motor
mount screws (2).
8. Snap the platen open belt cover (1) into the slots in the side plate.
9. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
10. Return the printer to normal operation (page 153).
List Of Adjustments
157
Legend:
1) Belt Cover
2) Motor Mount Screw (2)
3) Platen Open Motor Shaft
Figure 22. Platen Open Belt Adjustment
$
Direction of Force
1
$
2
3
2
158
Chapter 6 Paper Drive Motor Pulley Alignment
Paper Drive Motor Pulley Alignment
To make this adjustment, follow these steps:
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Remove the timing belt cover (1) by squeezing the front and back to
release the plastic tabs from the slots in the side plate.
4. Loosen the screw (2) in the motor pulley collar (3).
5. Align the paper drive motor pulley (4) with the splined shaft pulley (5).
ATTENTION
Make sure there is at least 0.040 inches (1.016 mm) of clearance
between the collar (3) and the motor face plate.
6. Hold the collar (3) flush against the motor pulley (4) and tighten the screw
(2).
7. Check for correct tension on the paper feed timing belt (page 154). Adjust
if necessary.
8. Snap the timing belt cover (1) into the slots in the side plate.
9. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
10. Return the printer to normal operation (page 153).
List Of Adjustments
159
Legend:
1) Belt Shield
2) Cap Screw
3) Motor Pulley Collar
4) Motor Pulley
5) Splined Shaft Pulley
Figure 23. Paper Drive Motor Pulley Alignment
$
$
1
2
3
5
4
160
Chapter 6 Paper Scale Alignment
Paper Scale Alignment
To make this adjustment, follow these steps:
1. Open the printer cover.
2. Load paper and ribbon.
3. Connect the power cord to the AC power source.
4. Set the printer power switch to 1 (on).
5. Verify that the shuttle cover (1) is properly installed (page 203).
6. Print a full 136 column line by selecting and running one of the diagnostic
self-tests. (See Chapter 5.)
7. Check alignment of the scale to the print at column positions 1 and 136.
8. If adjustment is necessary, loosen the three button-head 5/64 inch hex
screws (2).
9. Position the scale (3) so that column positions 1 and 136 line up with the
first and last characters on the 136 character printout.
10. Tighten the 5/64 inch button-head screws (2).
11. Close the printer cover.
List Of Adjustments
161
Legend:
1) Shuttle Cover
2) Screw, Button-Head, 5/64 inch hex (3)
3) Paper Scale
Figure 24. Paper Scale Alignment
1
2
2
2
3
162
Chapter 6 Platen Gap Adjustment
Platen Gap Adjustment
To make this adjustment, follow these steps:
IMPORTANT
Only do this procedure if the original equipment shuttle frame assembly
or platen has been replaced by a new or refurbished unit.
1. Prepare the printer for maintenance (page 152).
2. Remove the shuttle cover assembly (page 203).
3. Loosen the platen open belt (page 156, steps 2, 3, and 4).
4. Raise the forms thickness lever (1) to the fully open position.
ATTENTION
Do not force the platen against the feeler gauge. Damage to the hammer
tips will result.
5. Insert a 0.011 inch (0.28 mm) flat feeler gauge (2) straight down between
the hammer bank cover plate (3) and ribbon mask (4), within four hammer
positions of the left end of the hammer bank.
ATTENTION
Adjust the platen set screws less than 1/4 turn on one side, then check
the other side. Adjustment sensitivity is approximately 0.03 inch per
revolution of the set screw. Also, insert the feeler gauge no more than 2
inches down from the top of the ribbon mask.
6. Gently close the forms thickness lever (1). As the platen is closing, gently
slide the feeler gauge up and down, keeping it between the hammer tip
and ribbon mask. If the feel is too tight when the platen is being closed,
adjust the 3/32 inch set screw (5) at the end of the platen
counterclockwise. If the feel is too loose, adjust the set screw clockwise.
With the forms thickness lever closed all the way, the feeler gauge should
contact both the tips and the ribbon mask and move with light friction.
Shift the gauge slightly to verify.
7. Repeat steps 4 through 6 at the right end of the hammer bank.
8. After adjusting both sides, check the gap again at both ends. Readjust if
necessary.
9. When the platen gap is correct at both ends of the platen, adjust the
platen open belt (page 156).
10. Install the shuttle cover assembly (page 203).
11. Check the hammer phasing adjustment (page 173).
12. Return the printer to normal operation (page 153).
List Of Adjustments
163
Legend:
1) Forms Thickness Lever
2) Feeler Gauge (0.011 inch or 0.28 mm)
3) Hammer Bank Cover
4) Ribbon Mask
5) Set Screw, 3/32 inch hex (2)
Figure 25. Platen Gap Adjustment
55|cc3
MOy 4, 1
$
$
NOTE: Left side adjustment
shown. Right side is the same.
1
2
3
4
5
164
Chapter 6 Platen Open Motor Pulley Alignment
Platen Open Motor Pulley Alignment
To make this adjustment, follow these steps:
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Go to step 3.
Pedestal Model: Remove the top cover assembly (page 204).
3. Remove the platen open belt cover (1) by squeezing the top and bottom
to release the plastic tabs from the slots in the side plate.
4. Loosen the 1/16 inch set screw (2) in the motor pulley.
5. Bottom out the platen open motor pulley (3) on the motor shaft and torque
the 1/16 inch set screw (2) to 9 2 inch-pounds (1.02 0.23 Nm).
6. Check the platen open belt tension (page 156). Adjust if necessary.
7. Snap the platen open belt cover (1) into the slots in the side plate.
8. Cabinet Model: Go to step 9.
Pedestal Model: Install the top cover assembly (page 204).
9. Return the printer to normal operation (page 153).
List Of Adjustments
165
Legend:
1) Belt Cover
2) Set Screw
3) Platen Open Motor Pulley
4) Platen Shaft Pulley
Figure 26. Platen Open Motor Pulley Alignment
$
$
1
4
3
2
166
Chapter 6 Ribbon Guide Alignment
Ribbon Guide Alignment
To make this adjustment, follow these steps:
1. Open the printer cover.
2. Load paper and install the ribbon. To align a ribbon guide, wind the ribbon
fully onto the ribbon spool on the opposite side. For example, to align the
left ribbon guide, wind the ribbon until the right ribbon spool is full.
3. Check ribbon tracking by running the PRINTER MECHANISM TESTS :
Shuttle Slow (page 134).
4. On the ribbon quide to be adjusted, momentarily short between the ribbon
guide skid screws (1) to verify that the ribbon reverses.
5. Observe how the ribbon (2) passes around and across the ribbon guide. It
should be centered and not folding against either of the two white nylon
washers (3).
6. If the ribbon is not centered, loosen the retaining screws (4) just enough
so that you can rotate the ribbon guide to new positions, but it remains in
place once moved.
7. Rotate the ribbon guide as required to center the ribbon (2).
8. Observe how the ribbon (2) winds onto the ribbon spool of the side you
adjusted. If the ribbon is interfering with the flange of the spool, make sure
the ribbon hub and spool are mounted correctly.
9. Tighten the retaining screws (4).
10. Allow most of the ribbon to wind onto the ribbon spool on the side you
adjusted, then repeat steps 3 through 9 for the other ribbon guide.
List Of Adjustments
167
Legend:
1) Screw, Skid (2)
2) Ribbon
3) White Nylon Washer
4) Screw, Retaining (2)
Figure 27. Ribbon Guide Alignment
$
$
%
Left Ribbon Guide Right Ribbon Guide
%
2
3
2
4
4
Early
Models
Later
Models
1
3
1
168
Chapter 6 Splined Shaft Skew Adjustment
Splined Shaft Skew Adjustment
If lines of print are not parallel with the edge perforations on the paper,
perform the following adjustment.
1. Open the printer cover.
2. Loosen the screw (1) securing the adjusting link (2).
3. Adjust the link (2) by raising or lowering the horizontal adjustment knob
(3) to obtain print parallel with paper perforations. Tighten the screw (1).
4. Return the printer to normal operation (page 153).
Legend:
1) Screw
2) Adjusting Link
3) Horizontal Adjustment Knob
Figure 28. Splined Shaft Skew Adjustment
2
1
3
List Of Adjustments
169
Adjusting The End Of Forms Distance
This procedure tests and sets the distance from the page perforation at which
an END OF FORMS fault message is triggered. This adjustment prevents
printing on the platen when the printer runs out of paper. The measurement
units are dot rows.
You will use the dot row patterns printed by the END OF FORMS ADJUST
self-test to verify that this parameter is set correctly.
NOTE: Do this procedure only if a new paper detector switch assembly has
been installed, or if you are sure that the end of forms adjustment is
incorrect. An END OF FORMS triggering distance of 1 or 2 dot rows
from the perforation is acceptable; 5 to 7 dot rows off indicates
adjustment is required.
Also, although it is not required, it is advisable to test the End of
Forms distance with 6-part paper, in order to verify correct printing
with multi-part forms.
The procedure below describes how to run the END OF FORMS ADJUST
printer test and modify the END OF FORMS ADJUSTMENT VALUE.
1. Power on the printer.
2. Load paper and set the top of form. Make sure the forms thickness lever
is closed. Open the cabinet front door.
3. On the sheet of paper just below the paper entrance slot, tear a four-inch
square on the left side, immediately below the perforation. (See Figure
29.) This creates a hole that will trigger an END OF FORMS condition, but
allows printing to the right of the hole (which would normally be on the
platen).
4. Tear a four inch square in the manner described above, on every third
sheet, until you have made 3 or 4 holes.
5. If the printer is in READY mode, press Stop to put it into NOT READY
mode.
6. Press Scroll + Scroll to unlock the Enter key.
7. Press Scroll + Scroll + Return + Enter to enter the CE Tests menu.
(Press all four keys at the same time.)
170
Chapter 6 Adjusting The End Of Forms Distance
Figure 29. Paper Preparation for Paper Out Adjustment Test
Page Perforation
Page Perforation
Page Perforation
Cut out here
4 in.
4 in.
List Of Adjustments
171
8. The display will show SERVICE / PRINTER MECHANISM TESTS, the
first menu item. Press Enter to enter the mechanism tests menu.
9. Press Scroll or Scroll until
PRINTER MECHANISM TESTS / END OF FORMS ADJUST is on the
display.
This test will print a vertical comb pattern at around column 70, each
long bar separated by three shorter bars. An enlarged example of the
comb pattern is shown below.
10. Press Enter until the END OF FORMS ADJUST test starts.
The comb pattern will print until the display shows
001 END OF FORMS / LOAD FORMS and (if enabled) the audible
alarm sounds. If the alarm sounds, press Stop to silence it.
11. Remove the paper from the tractors and examine the area of the page
perforation. (If the alarm sounds when you open the platen, press Stop to
silence it.)
If a bar from the comb pattern just meets the perforation, the end of forms
adjustment distance is correct. (A bar exactly on perforation is ideal; 1 or
2 dot rows off is OK; 5 to 7 dot rows off is too much.) Unless you wish to
restart the procedure with 6-part paper, you may stop the test here, and
skip to step 22. (See the note at the beginning of this procedure.)
If the comb pattern stopped short of the perforation or printed beyond the
perforation, go to step 12.
12. Measure how short or long the comb pattern printed by counting the
number of dot rows needed to reach the perforation, or the number of dot
rows that printed beyond the perforation.
NOTE: You can use the long bars to count the dot rows quickly. There are
three dot rows between each long bar, so each long bar increases the
number of dot rows by four. You can also tear off a small piece of the
comb pattern from the beginning of the pattern and use it as a ruler to
help you measure the dot rows required either to reach the
perforation or back up to it.
13. Reload the paper and set the top of form.
14. Press Scroll + Scroll + Return + Enter to enter the CE Tests menu.
(Press all four keys at the same time.)
15. The display will show SERVICE / PRINTER MECHANISM TESTS, the
first menu item. Press Scroll or Scroll until
SERVICE / END OF FORMS ADJUSTMENT VALUE is on the display.
16. Press Enter. The top line of the display will show
END OF FORMS ADJUSTMENT VALUE and the bottom line will show
the current setting for the number of dots.
Short Bar
Long Bar
172
Chapter 6 Adjusting The End Of Forms Distance
17. Press Enter. The number of dots will move up to the top line of the
display.
18. Using the Scroll or Scroll key, adjust the XX DOTS value up or down
by the number of dots you counted in step 12. (If the comb pattern
stopped short of the perforation, increase the number of dots. If the comb
pattern printed beyond the perforation, decrease the number of dots.)
19. Press Enter to select the new number of dots as the active value. (The
asterisk that appears tells you that it is now the active value.)
20. Press Stop to put the printer into NOT READY mode.
21. Run the END OF FORMS ADJUST and the
END OF FORMS ADJUSTMENT VALUE tests until the comb pattern
prints at an acceptable distance from the page perforation. (Return to
step 7.)
22. When the End of Forms Adjustment is acceptable, reload the paper, feed
it past any remaining unused holes that you tore in it, and set the top of
form.
23. Press Scroll + Scroll to lock the Enter key.
24. Press Start to put the printer into READY mode.
List Of Adjustments
173
Hammer Phasing Adjustment
You must check and adjust hammer phasing if the CMX controller board is
replaced, the shuttle frame assembly is removed, or if the MPU is replaced.
The hammer phase value is a timing parameter that permits you to adjust the
horizontal alignment of dots in character printing. The phase value numerical
units are relative; they do not represent a physical measurement or value.
Thus there is no correct value or range. But, if the phasing value is far
enough from the theoretical ideal value on a particular printer, errors can
occur. If, for example, you are adjusting phasing and an error such as
124 PAPER FIFO UNDERFLOW occurs, the phase value may be too high.
Try a lower value.
The factory prints the initial phase value on the aluminum casting of the
shuttle assembly, next to the motor housing. Adjust the phasing to this value
and recheck the horizontal alignment. When alignment is acceptable, write
the new phasing value on the shuttle.
Phasing should be adjusted with the printer printing at full paper width.
IMPORTANT
The printer must be printing the Phase pattern of Hs when the
Phasing Value is changed, or the New Phasing Value will not be written
into NVRAM. If the value is changed when not printing, the printer will
return to its default phasing value when powered off then back on.
1. Install the ribbon.
2. Load full width (136 column) paper.
3. Power on the printer and set top of form.
4. Press Stop to put the printer into NOT READY mode.
5. Press Scroll + Scroll to unlock the Enter key.
6. Press Scroll + Scroll + Return + Enter to enter the CE Tests menu.
(Press all four keys at the same time.)
7. The display will show SERVICE / PRINTER MECHANISM TESTS, the
first menu item. Press Enter to enter the mechanism tests menu.
8. Press Scroll or Scroll until
PRINTER MECHANISM TESTS / HAMMER PHASING is on the
display.
9. Press Enter. The printer begins printing all Hs, each line preceded by the
phasing index number.
10. Press Return. The display will show
SERVICE / PRINTER MECHANISM TESTS.
11. Press Scroll or Scroll until SERVICE / HAMMER PHASE VALUE is
on the display.
12. Press Enter. The top line of the display will show
HAMMER PHASE VALUE and the bottom line will show the current
phasing index number.
174
Chapter 6 Hammer Phasing Adjustment
13. Press Enter. The phasing index (followed by an asterisk) will move up to
the top line of the display.
14. Press Scroll or Scroll to increase or decrease the phasing index, then
press Enter to activate the value as it prints. Continue to increase or
decrease the phasing index until the pattern of Hs appears as shown
below:
15. When the print pattern is acceptable, press Stop. Printing stops, and the
printer automatically enters the current phase index value into NVRAM.
The display shows NOT READY.
16. Press Scroll + Scroll to lock the Enter key.
17. Close the printer cover. Press Start to put the printer into READY mode.
NOTE: If you changed the phasing value, power down the printer, remove
the shuttle cover, and write the new phase value on the aluminum
shuttle casting.
Needs
Adjustment
Correct
Needs
Adjustment
List Of Adjustments
175
Downloading 6400 Microcode From The World Wide Web
This section describes the procedure for obtaining microcode for all models of
the 6400 printer. This process is done through Lotus Notes IBM First Service
system.
NOTE: It is helpful to create a directory named 6400 on the laptop to hold
your 6400 code downloads. If you do not know how to create
directories, see your ESPI or someone familiar with PCs.
1. Open Lotus Notes.
2. Open the IBM First Service System II data base.
3. Click on the button at the left of your screen that says uCode.
4. PSC machine and RIM Notes Code Microcode should now be showing.
5. Highlight Machine Records via the WEB (Primary Site)click on the
OK button.
6. When the next screen reads PSC Machine Microcode scroll down to the
6400 machine type and click on ICON.
7. Netscape will open the Code download site.
8. Find the code you need in the list, move your mouse pointer so it points to
the icon of the needed file, and double-click with the left mouse button.
9. At the prompt Unknown File Type click once on the Save File... button.
10. At the Save As... window, point to the down arrow just to the right of the
Save In pane and select the folder (the directory; for example, the 6400
folder) in which to save the file.
11. After you select the folder to receive the file, verify that the File name
window has the the correct name, then click on the Save button.
12. The file will download to the directory you requested. You can now load
flash memory (page 176).
176
Chapter 6 Loading Flash Memory
Loading Flash Memory
Emulation and operating system software are loaded into flash memory at the
factory, but you will install software in the following situations:
The customer needs to upgrade printer software
The customer needs different emulation software
You have replaced the controller board
You have added or replaced a flash memory SIMM
Emulation and operating system software are stored as a compressed file.
The file is executable; you will expand it and copy it into printer flash
memory with a single command.
1. Download the correct level of microcode from the World Wide Web (page
175).
2. If the printer has an internal Ethernet interface card, refer to the Ethernet
Users Manual for download instructions. If you loading flash memory
through the parallel or serial port, continue with this procedure.
3. Make a printout of all saved configurations. (Refer to the Setup Guide.)
(Installing new software erases all saved configurations. You will use the
printouts to restore printer configuration.)
4. Set the printer power switch to O (off).
5. Unplug the AC power cord from the printer.
6. If the printers parallel data cable is connected to the parallel port of an
IBM-compatible computer using the PC-DOS* or MS-DOS** operating
system, skip to step 10. If not, go to step 7.
7. Disconnect all data input cables from the printer interface.
8. Connect the parallel data cable to the default parallel port (LPT1) of an
IBM-compatible computer using the PC-DOS or MS-DOS operating
system.
NOTE: You can connect the data cable to the LPT2 port if the LPT1 port is
already in use. You can also download software through the printer
serial port. The download commands are different if you use these
ports, as described in the note after step 17.
<4> Do not connect or disconnect any communications port,
teleport, attachment connector, or power cord during an
electrical storm.
<5> Power off the printer and disconnect the power cord before
connecting or disconnecting a communication port,
teleport, or attachment cable connector.
DANGER
List Of Adjustments
177
9. Connect the parallel data cable to the parallel port of the printer.
10. Plug the AC power cord into the printer.
11. Power on the computer.
12. On the printer control panel, press and hold down the Start + Cancel
keys. Without releasing the keys, power the printer on. Continue holding
the Start and Cancel keys down for five seconds, then release them.
NOTE: The port default is CENTRONICS; this is the standard download
through the parallel port. If you want to use the default, continue at
step 17.
13. When you see WAITING FOR PROGRAM DOWNLOAD on the LCD,
press the Scroll key; SELECT DOWNLOAD PORT=DATAPRODUCT
appears on the LCD.
14. Press Scroll again to cycle through the download ports available in the
printer:
DATAPRODUCT (parallel)
CENTRONICS* (parallel) (default port)
RS232-9600 (RS-232 serial, 9600 baud)
RS232-19.2K (RS-232 serial, 19200 baud)
RS232-38.4K (RS-232 serial, 38400 baud)
RS232-115K (RS-232 serial, 115000 baud)
RS422-9600 (RS-422 serial, 9600 baud)
RS422-19.2K (RS-422 serial, 19200 baud)
RS422-38.4K (RS-422 serial, 38400 baud)
RS422-115K (RS-422 serial, 115000 baud)
15. Press Scroll + Scroll to unlock the Enter key.
16. When the printer download port you want to use is displayed on the LCD,
press ENTER. WAITING DOWNLOAD / PORT = <your selection>
appears on the display.
17. At the DOS prompt on the computer type:
FILENAME.EXE -pb<return>
where FILENAME.EXE is the file you downloaded from the World Wide
Web. This command expands the file and copies it as a binary file into the
flash memory on the CMX controller board.
NOTE: If you are downloading the file using the LPT2 port on the computer,
enter the following DOS command:
FILENAME.EXE -pb 2 <Return>
If you are downloading the file into the printer serial port, enter the
following DOS commands:
MODE COM1:9600,N,8,1,P<Return>
FILENAME.EXE -PBC1<Return>
18. While the file is copied into memory, the printer LCD informs you of the
load process and status. (See Table 7 below.)
19. When the file has successfully loaded into memory and the printer has
reset itself, set the printer power switch to O (off).
20. Unplug the AC power cord from the printer.
21. Power off the personal computer.
178
Chapter 6 Loading Flash Memory
22. If you had to install a parallel data cable to the computer and printer in
step 8, disconnect it from the computer and printer.
23. Reconnect the customers data input cable(s) to the printer, if required.
24. Return the printer to normal operation (page 153).
25. Using the configuration printout(s) you made in step 3, reconfigure the
printer. (Refer to the Setup Guide.)
NOTE: A continuous IML cycle indicates coax/twinax code is being loaded
into a printer with a missing, defective, or improperly installed Coax/
Twinax board. If the printer is supposed to have this feature, reseat
the Coax/Twinax board. If the printer is not supposed to have this
feature, install new emulation code without the Coax/Twinax feature.
Table 7. Flash Memory Message Guide
Message Explanation
Required
Action
CLEARING PROGRAM
FROM FLASH
The program successfully loaded into
printer RAM and the checksum
matched. The old program is now
being deleted from flash memory.
None
DIAGNOSTIC
PASSED
The printer passed its memory and
hardware initialization tests.
None
ERROR: DC PROGRAM
NOT VALID
Printer cannot find the data controller
program or the validation checksum is
corrupted.
Download the program
again: Power off the
printer and start over at
step 12. If the message
occurs again, replace the
flash memory.
ERROR: DRAM AT
ADDRESS XXXXXXXX
The printer found a defective memory
location.
Replace the DRAM.
ERROR: EC PROGRAM
NOT VALID
Printer cannot find the engine
controller program or the validation
checksum is corrupt.
Download the program
again: Power off the
printer and start over at
step 12. If the message
occurs again, replace the
flash memory.
ERROR: EC STOPPED
AT STATE XXXX
Hardware fault in the engine
controller.
Replace the CMX
controller board.
ERROR: FLASH
DID NOT PROGRAM
The printer encountered an error
trying to program flash memory.
Download the program
again: Power off the
printer and start over at
step 12. If the message
occurs again, replace the
flash memory.
List Of Adjustments
179
ERROR: FLASH
NOT DETECTED
The printer could not find any flash
memory.
Install flash memory
before attempting to
download this program.
ERROR: NO DRAM
DETECTED
The printer could not find any DRAM. Check DRAM on CMX. If
present, reseat DRAM, If
missing, install DRAM.
ERROR: NVRAM
FAILURE
The non-volatile memory has failed. Replace the CMX
controller board. (Do
NOT attempt to replace
NVRAM.)
ERROR: PROGRAM
NEEDS MORE DRAM
The printer requires more DRAM
memory in order to run the
downloaded program.
Add DRAM or use a
smaller emulation
program.
ERROR: PROGRAM
NEEDS MORE FLASH
The printer requires more flash
memory in order to run the
downloaded program.
Add flash memory or use
a smaller emulation
program.
ERROR: PROGRAM
NOT COMPATIBLE
The printer is not compatible with the
downloaded program. User tried to
load CMX-compatible diskette in
CBO-controlled printer, or vice versa.
Use the correct emulation
software option(s) for this
model. If the printer is an
IBM 6404-B01, the
controller is a CBO
board. If the printer is an
IBM 6400, the controller
is a CMX board.
ERROR: PROGRAM
NOT VALID
The printer does not see a program in
flash memory.
There is no program in
printer memory. Go to
step 4.
ERROR: SECURITY PAL
NOT DETECTED
The security PAL is not present or has
failed.
Check the security PAL at
location U54 on the CMX
controller. If the PAL is
absent, install the correct
PAL. If security PAL is
present, replace the CMX
controller board.
ERROR: SHORT AT
ADDRESS XXXX
Hardware failure in DRAM or CMX
controller circuitry.
Replace DRAM. If
message occurs with
new DRAM, replace CMX
controller board.
Table 7. Flash Memory Message Guide
Message Explanation
Required
Action
180
Chapter 6 Loading Flash Memory
ERROR: WRITING
TO FLASH
Hardware or software fault in flash
memory.
Download the program
again: Power off the
printer and start over at
step 12. If the message
occurs again, replace the
flash memory.
ERROR: WRONG
CHECKSUM
The printer received the complete
program but the checksum did not
match. The data were corrupted
during download.
Download the program
again: Power off the
printer and start over at
step 12.
ERROR OCCURRED
FLUSHING QUEUES*
An interim message that displays
while the printer discards host data it
cannot use because a fault condition
exists. While this message displays,
the asterisk (*) rotates.
Wait. When the asterisk
(*) stops rotating, a
different fault message
will appear: troubleshoot
the final message.
LOADING PROGRAM
FROM PORT XX%
The new program is loading into
printer RAM. XX indicates how much
of the program has loaded.
None
LOADING PROGRAM
INTO FLASH
The printer has deleted the previous
program from flash memory and is
loading the new program into flash
memory.
None
RESETTING . . .
PLEASE WAIT
The printer finished loading the
program into flash memory and is
automatically resetting itself.
None
RESTORING
BOOT CODE
Normal download initialization
message.
None
SECURITY CODE
VIOLATION
The software running or being
downloaded does not match the
security PAL code.
Install the correct PAL or
program. (PAL and
program must match.)
SENDING PROGRAM
TO EC PROCESSOR
The printer is loading the engine
controller program into the engine
controller.
None
TABLE MISMATCH
DOWNLOAD AGAIN
EC software update in process. Download the program
again: Power off the
printer and start over at
step 12.
Table 7. Flash Memory Message Guide
Message Explanation
Required
Action
List Of Adjustments
181
Coil Temperature Adjustment
This procedure applies only to models 6400-014 and 6400-015. Do this
procedure only when the original CMX controller board or shuttle frame
assembly have been replaced. Do not do this procedure if the original CMX
board or shuttle frame assembly were removed and reinstalled as part of
other maintenance tasks.
The shuttle frame assembly must be at room temperature to do this
procedure.
1. Raise the printer cover.
2. Power on the printer.
3. If the Ready indicator is on, press the Stop key. The printer must be in
the NOT READY state to do this procedure.
4. Press Scroll + Scroll + Return + Enter. (Press all four keys at the
same time.) SERVICE / PRINTER MECHANISM TESTS appears on the
display.
5. Press Scroll + Scroll to unlock the Enter key.
6. Press the Scroll or Scroll key until SERVICE / SET COIL
TEMPERATURE appears on the display.
7. Press Enter. The display tells you to PLEASE WAIT while the coil
temperature is set by an automatic calibration sequence in printer
software.
8. When the display again reads SERVICE / SET COIL TEMPERATURE
press Scroll + Scroll to lock the Enter key.
9. Press Stop to exit the menu and put the printer in the NOT READY state.
- OR -
10. Press Start to exit the menu and put the printer in the READY state.
11. Coil temperature is now set. Power off the printer and close the printer
cover.
182
Chapter 6 Set Shuttle Speed
Set Shuttle Speed
This procedure applies only to models 6400-004, -04P, -005, and -05P.
Do this procedure only when the original CMX controller board or shuttle
frame assembly have been replaced. Do not do this procedure if the original
CMX board or shuttle frame assembly were removed and reinstalled as part
of other maintenance tasks.
1. Install the ribbon and load full-width paper.
2. Power on the printer.
3. If the Ready indicator is on, press the Stop key. The printer must be in
the NOT READY state to do this procedure.
4. Press Scroll + Scroll + Return + Enter. (Press all four keys at the
same time.) SERVICE / PRINTER MECHANISM TESTS appears on the
display.
5. Press Scroll + Scroll to unlock the Enter key.
6. Press the Scroll or Scroll key until SERVICE / SHUTTLE SPEED
appears on the display.
7. Press Enter. SHUTTLE SPEED / 475* or SHUTTLE SPEED / 500*
appears on the display. The asterisk [*] indicates which shuttle speed is
currently active.
8. Press Scroll until the shuttle speed you want appears on the display.
9. Press the Enter. An asterisk [*] appears next to the selection, indicating it
is now the active shuttle speed.
10. Press Scroll + Scroll to lock the Enter key.
11. Press Stop to exit the menu and put the printer in the NOT READY state.
12. Power off the printer, wait a few seconds, then power on the printer to
activate the new shuttle speed value.
13. Select and run the Ripple Print printer test (page 132).
14. Examine the printout: if gaps or dark bars appear in the printout, go back
to step 3 and set the shuttle speed to the other option.
15. When the printout is acceptable, power off the printer and close the
printer cover.
List Of Adjustments
183
Ethernet Initialization
To initialize the Ethernet interface, do the following steps:
1. Power on the printer.
2. Wait for READY / ETHERNET ADAPTER IS READY to display on the
LCD.
3. If the Ready indicator is on, press the Stop key. The printer must be in
the NOT READY state to do this procedure.
4. Press Scroll + Scroll + Return + Enter. (Press all four keys at the
same time.) SERVICE / PRINTER MECHANISM TESTS appears on the
display.
5. Press Scroll + Scroll to unlock the Enter key.
6. Press the Scroll or Scroll key until SERVICE / PRINTER MGMT
appears on the display.
7. Press Enter. PRINTER MGMT / DIAGNOSTIC PORT appears on the
display.
8. Press Enter. DIAGNOSTIC PORT (and the current diagnostic port
setting) appears on the display. If the current setting is DEBUG
ETHERNET*, go to step 11.
9. Press Scroll until DIAGNOSTIC PORT / DEBUG ETHERNET appears
on the display.
10. Press Enter. An asterisk (*) appears next to the selection, indicating it is
now the diagnostic port.
11. Press Scroll + Scroll to lock the Enter key.
12. Press Stop to exit the menu and put the printer in the NOT READY state.
13. Power off the printer, wait a few seconds, then power on the printer to
activate the new diagnostic port.
184
Chapter 6 Ethernet Initialization
185
7 Replacement Procedures
And Illustrated Parts Lists
Organization Of This Chapter
This chapter is divided into two sections.
Section I: Replacement Procedures
This section contains written procedures for removing and installing
components that are replaceable at the field service level of maintenance.
The procedures in this section refer you to the illustrations in Section II.
Section I begins on page 186.
Section II: Illustrated Parts Lists
This section contains drawings of all assemblies comprising the printer.
On the page facing each illustration is a list of the illustrated parts and
their part numbers.
Section II begins on page 249.
IMPORTANT
The components specified in this chapter are field replaceable units
(FRUs). FRUs must be repaired at the factory. Do not attempt field repair
of these items.
186
Chapter 7 Section I: Replacement Procedures
Section I: Replacement Procedures
This section contains removal/installation procedures for components that are
replaceable at the field service maintenance level. These procedures are
listed below.
IMPORTANT
Do not attempt field repairs of electronic components or assemblies.
Replace a malfunctioning electronic assembly with an operational
spare. Most electronic problems are corrected by replacing the circuit
board, sensor, or cable that causes the fault indication. The same is true
of failures traced to the hammer bank coils and electronics: you must
replace the entire shuttle frame assembly. It is not field repairable.
(Hammer spring assemblies are the only replaceable components of the
shuttle frame assembly.)
List Of Procedures
Belt, Paper Feed Timing ................................................................. page 188
Belt, Platen Open............................................................................ page 189
Circuit Board: Controller.................................................................. page 190
Circuit Board: Power Supply ........................................................... page 192
Circuit Breaker ................................................................................ page 193
Coax/Twinax Multi-Platform Interface ............................................. page 194
Connector Shells............................................................................. page 195
Connector Stiffening Clips............................................................... page 198
Cover Assembly, Hammer Bank / Ribbon Mask ............................. page 200
Cover Assembly, Shuttle................................................................. page 203
Cover Assembly, Top, Pedestal Model ........................................... page 204
Dashpot........................................................................................... page 205
Doors, Cabinet, Reversing.............................................................. page 206
Ethernet Interface Assemblies ........................................................ page 207
Fan Assembly, Cabinet Exhaust ..................................................... page 208
Fan Assembly, Card Cage.............................................................. page 209
Fan Assembly, Hammer Bank ........................................................ page 210
Hammer Spring Assembly .............................................................. page 211
IBM Coax/Twinax Expansion Board................................................ page 215
Magnetic Pick-up (MPU) Assembly................................................. page 216
Memory and Security Modules........................................................ page 217
Motor Assembly, Paper Feed.......................................................... page 221
Motor Assembly, Platen Open ........................................................ page 223
List Of Procedures
187
Motor Assembly, Ribbon Drive........................................................ page 225
Network Print Server ....................................................................... page 226
Operator Panel Assembly, Cabinet Model ...................................... page 227
Operator Panel Assembly, Pedestal Model .................................... page 228
Paper Guide Assembly ................................................................... page 229
Paper Ironer .................................................................................... page 230
Platen.............................................................................................. page 231
Resistors, Terminating .................................................................... page 235
Ribbon Guide Assembly (L/R)......................................................... page 237
Ribbon Hub ..................................................................................... page 238
Security Module .............................................................................. page 217
Shaft, Splined.................................................................................. page 239
Shaft, Support ................................................................................. page 241
Shuttle Frame Assembly ................................................................. page 242
Spring, Extension............................................................................ page 244
Switch Assembly, Cover Open........................................................ page 245
Switch Assembly, Paper Detector ................................................... page 246
Switch Assembly, Platen Interlock .................................................. page 247
Tractor (L/R) .................................................................................... page 248
188
Chapter 7 Section I: Replacement Procedures
Belt, Paper Feed Timing
Removal
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Cabinet Model: Loosen four screws and remove the barrier shield.
(See page 258, Figure 44, items 3 and 4.)
Pedestal Model: Loosen the four screws securing the paper guide and
barrier shield. Remove the paper guide and barrier shield. (See page 260,
Figure 45, items 3, 4, and 5.)
4. Remove the timing belt cover by squeezing the front and back to release
the plastic tabs from the slots in the side plate (page 258, Figure 44).
5. Loosen (do not remove) the paper feed motor mount screws (page 278,
Figure 52, item 10).
6. Loosen the setscrew in the paper feed motor pulley collar.
7. Remove the paper feed timing belt by sliding the paper feed motor pulley
off the motor shaft and the belt off the splined shaft pulley.
Installation
1. Install the paper feed timing belt over the splined shaft pulley and the
motor pulley. Slide the motor pulley onto the paper feed motor shaft (page
278, Figure 52).
2. Holding a 0.040 inch feeler gauge between the pulley collar and the motor
body, torque the 7/64 inch collar screw to 25 2 inch-pounds (2.82
0.23 Nm).
3. Using the straight end of a force gauge, apply 15 pounds (66.7 N) of
pressure to the paper feed drive motor near the mounting base of the
motor. Use the splined shaft to steady the gauge.
4. Reduce tension to 12 pounds (53.4 N) and torque the paper feed motor
mount bolts to 18 2 inch-pounds (2.03 0.23 Nm).
5. Snap the timing belt cover into the slots in the side plate (page 258,
Figure 44).
6. Cabinet Model: Install the barrier shield and tighten the four screws.
(See page 258, Figure 44, items 3 and 4.)
Pedestal Model: Install the barrier shield and paper guide and tighten the
four screws. (See page 260, Figure 45, items 3, 4, and 5.)
7. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
8. Return the printer to normal operation (page 153).
Belt, Platen Open
189
Belt, Platen Open
Removal
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Remove the platen open belt cover by squeezing the top and bottom to
release the plastic tabs from the slots in the side plate. (See page 276,
Figure 51, item 24.)
4. Loosen (do not remove) the two motor mount screws (page 278, Figure
52, item 15).
5. Push the motor toward the front of the printer to loosen the platen open
belt.
6. Loosen the setscrew in the platen open motor pulley.
7. Remove the platen open belt by sliding the platen motor pulley off the
motor shaft and the belt off the platen open pulley.
Installation
1. Slide the platen open timing belt over the platen open pulley and the
motor pulley and tighten the 1/16 inch setscrew.
2. Slide the motor pulley onto the platen open motor shaft and tighten the
pulley setscrew.
ATTENTION
Too much tension on the platen open belt can cause the platen gap to
change, which can lead to premature wear of the platen, damaged
hammer tips, and poor print quality.
3. Using a force gauge, apply 10 pounds (44.48 N) of tension to the motor
shaft by pushing in the direction away from the large platen pulley.
4. Reduce tension to 5 pounds (22.24 N) and torque the motor mount
screws to 11 2 inch-pounds (1.24 0.23 Nm).
5. Snap the platen open belt cover into the slots in the side plate.
6. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
7. Return the printer to normal operation (page 153).
190
Chapter 7 Section I: Replacement Procedures
Circuit Board: Controller
NOTE: 6400-050, -P50, -010, -P10, -014, -015, -C05, and C5P printers must
use the 40 MHz CMX controller board.
ATTENTION
To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling circuit boards, the
shuttle frame assembly, and any other electronic component.
Removal
1. Make a configuration printout of all configurations. (Refer to the
Operators Guide.)
2. Prepare the printer for maintenance (page 152).
3. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
4. Disconnect all cable connectors from the controller board. (See page 264,
Figure 47.)
5. Loosen, but do not remove, the screws securing the controller shield near
serial cable connector J201.
6. Loosen, but do not remove, the screw securing the controller shield to the
bottom of the card cage, on the left side near the card cage fan.
7. Slide the controller board to left until the keyway clears the screw
securing the controller board to the bottom of the card cage.
8. Remove the controller board.
9. Remove the DRAM SIMM, FLASH SIMM, and Security PAL from the
controller board (page 217). These will be installed on the replacement
controller board. The Security PAL must be installed on the replacement
controller board to ensure the printer functions correctly.
NOTE: When Flash SIMMs are removed from one controller board and
placed on another controller board, the SIMMs must be placed on the
new board in the same order and location as on the original board.
Circuit Board: Controller
191
Installation
ATTENTION
To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling circuit boards, the
shuttle frame assembly, and any other electronic component.
1. Install the DRAM SIMM, Flash Memory, and Security PAL on the
controller board (page 217).
2. Position the controller board assembly in the card cage, shield side down,
component side up. Engage the screw on the bottom of the card cage in
the keyway in the controller shield. Slide the board to right until the serial
cable connector J201 on the board lines up with the cutout in the card
cage. (See page 264, Figure 47.)
3. Tighten the screw securing the controller shield near serial cable
connector J201.
4. Tighten the screw securing the controller shield to the bottom of the card
cage.
5. Connect all cable connectors to the controller board, using the
Interconnection diagram on page 289 as your guide.
6. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
IMPORTANT
If the original CMX board was replaced, you must download the
emulation software again. Installing flash memory from the old board
onto the new board does not transfer all operating system software.
7. Load flash memory (page 176).
8. Models -014 and -015 only: adjust the coil temperature if the original CMX
board was replaced (page 181).
9. Models -004, -04P, -005, and -05P only: set shuttle speed if the original
CMX board was replaced (page 182).
10. Adjust the hammer phasing (page 173).
11. Adjust the end of forms distance (page 169).
12. Return the printer to normal operation (page 153).
13. Using the configuration printout you made as step 1 of the removal
procedure, reset and save the printer configuration.
192
Chapter 7 Section I: Replacement Procedures
Circuit Board: Power Supply
ATTENTION
Do not touch components or flex the board during removal/installation.
Handle the board by the ejection levers and the sides. Wear a properly
grounded static wrist strap when handling the power supply board.
Removal
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Disconnect output connector P101 from the controller board and AC input
connector P1 from the power supply board.
4. Loosen three captive screws securing the power supply board to the rear
wall of the card cage. (See page 264, Figure 47, item 15.)
5. Carefully disengage the power supply board from the three standoffs on
the rear wall of the card cage.
6. Remove the power supply board from the card cage.
Installation
1. Position the power supply board over the three standoffs on the rear wall
of the card cage and gently push the board until it engages fully on the
standoffs.
2. Install three screws securing the power supply board to the rear wall of
the card cage. (See page 264, Figure 47, item 15.)
3. Connect output connector P101 to the controller board and AC input
connector P1 to the power supply board.
4. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
5. Return the printer to normal operation (page 153).
<4> To prevent injury from electric shock, wait at least one
minute after powering off before removing the power
supply board.
CAUTION
Circuit Breaker
193
Circuit Breaker
Removal
1. Prepare the printer for maintenance (page 152).
2. Open the printer cover.
3. Remove the card cage fan (page 209).
4. Disconnect the four circuit breaker electrical leads.
(Cabinet Model: See Figure 53, page 280.
Pedestal Model: See Figure 46, page 262.)
5. Press in on the spring clips and remove the circuit breaker from the
printer.
Installation
6. Press the circuit breaker into the cutout until the spring clips snap into
place.
(Cabinet Model: See Figure 53, page 280.
Pedestal Model: See Figure 46, page 262.)
ATTENTION
Make sure the four leads are connected as shown on page 280 and page
262.
7. Connect the four circuit breaker electrical leads.
(Cabinet Model: See Figure 53, page 280.
Pedestal Model: See Figure 46, page 262.)
8. Install the card cage fan (page 209).
9. Return the printer to normal operation (page 153).
194
Chapter 7 Section I: Replacement Procedures
Coax/Twinax Multi-Platform Interface
NOTE: Installation, operation, and replacement parts for this optional feature
are covered in detail in the Coax/Twinax Multi-Platform Interface
Feature Installation and Operation Guide,
Form Number S246-0149.
Removal
ATTENTION
To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling circuit boards, the
shuttle frame assembly, and any other electronic component.
1. Prepare the printer for maintenance (page 152).
2. Refer to the Coax/Twinax Multi-Platform Interface Feature Installation and
Operation Guide, Form Number S246-0149.
Installation
1. Refer to the Coax/Twinax Multi-Platform Interface Feature Installation and
Operation Guide, Form Number S246-0149.
2. Return the printer to normal operation (page 153).
Connector Shells
195
Connector Shells
Some of the printer cable connectors are grouped inside connector shells.
The procedure below explains how to remove and install cable assemblies
from any connector shell in the printer.
NOTE: There is also a diagram of the P106 / P107 connector shells on the
plastic cover over the power supply. Additionally, later model printers
have stiffening clips attached to connectors P106 and P107. (See
page 198.)
Removal
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
NOTE: Later models have stiffening clips on connectors P106 and P107.
3. On later model printers, remove the stiffening clip (page 198).
4. Disconnect the cable connector shell containing the cable assembly that
will be replaced.
5. Pull the side of the connector shell outward and gently pull the cable
connector upward. (See Figure 30.) Notice that two-wire connectors are
grouped across from two-wire connectors in a connector shell. Four-wire
connectors are grouped across from four-wire connectors in a connector
shell.
6. Disengage the lock tab(s) on the cable connector from the slots in the
side of the connector shell.
7. Remove the cable connector from the connector shell. (Remove only the
cable connector for the cable you are replacing; leave the rest in the
shell.)
196
Chapter 7 Section I: Replacement Procedures
Installation
1. Position the cable connector in the connector shell. Two-wire connectors
are always grouped across from two-wire connectors in a connector shell.
Four-wire connectors are always grouped across from four-wire
connectors in a connector shell. (See Figure 30.)
2. Pull the side of the connector shell outward and gently push the cable
connector down into the connector shell.
3. Engage the tabs on the cable connector in the slots in the side of the
connector shell. Press the sides of the connector shell inward to make
sure all cable connector tabs are engaged in the shell slots.
NOTE: Later models have stiffening clips on connectors P106 and P107.
4. On later model printers, install the stiffening clip (page 198).
5. Connect the cable connector shell to its printer connection.
6. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
7. Return the printer to normal operation (page 153).
Connector Shells
197
Figure 30. Cable Connector Shell, Disassembly/Assembly
CCF = Card Cage Fan
LRIB M = Left Ribbon Motor
LRP = Left Ribbon Guide
PLAT M = Platen Open Motor
PMD = Paper Motion Detector (Switch)
POD = Paper Out Detect (Switch)
CVO = Cover Open (Switch)
EHF* = Exhaust Fan
HBF = Hammer Bank Fan
MPU = Magnetic Pickup
PAPR M = Paper Feed Motor
PLO = Platen Open (Switch)
RRIB M = Right Ribbon Motor
RRP = Right Ribbon Guide
* JMP on pedestal models: used as a
spacer
8 6 4 2
7 5 3 1
12 10 20 18 16 14
11 9 19 17 15 13
LRIB M
PLAT M
LRP
CCF
PMD
POD
P106 Connector Configuration
RRIB M
PAPR M
HBF
EHF
CVO
MPU
RRP
PLO
P107 Connector Configuration
Pin No.
8 6 4 2
7 5 3 1
12 10 20 18 16 14
11 9 19 17 15 13 (Top View: As seen
when plugged into the
CMX controller board.)
Later models have
stiffening clips on
connectors P106 and
P107. See page 198.
Typical 4-Wire
Cable Connector
Pull the sides outward just
enough to release the
connector lock tab from the
slot in the connector shell.
Connector shell
P106 / P107
P/N 202362-901
J106 or J107 on CMX
Controller Board
Key Tab
Typical 2-Wire
Cable Connector
Key Tab Slot
Push here to
remove the shell
from the controller
board.
198
Chapter 7 Section I: Replacement Procedures
Connector Stiffening Clips
Later model printers have connector stiffening clips on CMX board connectors
P106 and P107. For earlier models, the clips are available in a field kit. The
clips stiffen connectors P106 and P107 and help prevent accidental removal
of wires when the connector shells are disconnected from the CMX board.
Removal
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Unsnap the front (open side) of the clip from the connector shell, release
the back of the clip from the lip of connector shell P107, and work the
stiffening clip off the cable bundle. (See Figure 31.)
4. Repeat step 3 for the P106 connector.
5. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
6. Return the printer to normal operation (page 153).
Installation
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Work the stiffening clip over the cable bundle, engage the back of the clip
under the lip of connector shell P107, then snap the front (open side) of
the clip down over the connector shell. (See Figure 31.)
4. Repeat step 3 for the P106 connector.
5. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
6. Return the printer to normal operation (page 153).
Connector Stiffening Clips
199
Figure 31. Connector Stiffening Clips
P107
P106
Stiffening
Clip
$
$
$
Connector
Shell
200
Chapter 7 Section I: Replacement Procedures
Cover Assembly, Hammer Bank / Ribbon Mask
Removal
1. Prepare the printer for maintenance (page 152).
2. Remove the shuttle frame assembly (page 242).
3. Early models:
Lift the thick plate of the hammer bank cover assembly at one end, and
peel the cover away from hammer bank magnets. (See Figure 32, page
202.)
4. Later models:
a. Using a Torx T-10 driver, remove the six screws and three ribbon
mask clamp plates securing the ribbon mask to the hammer bank
cover. Remove the ribbon mask. (See Figure 32, page 202.)
NOTE: If you are replacing just the ribbon mask, simply loosen the six screws
until you can slip the ribbon mask off the alignment pins.
b. Using a Torx T-10 driver, remove the 12 screws securing the hammer
bank cover to the hammer bank. Remove the hammer bank cover.
(See Figure 32, page 202.)
Cover Assembly, Hammer Bank / Ribbon Mask
201
Installation
ATTENTION
The hammer bank contains a strong magnet. To prevent damage to the
hammer tips, do not let the hammer bank cover assembly snap into
place as the hammer bank magnet attracts it. Any impact of the cover
against the hammer bank can break hammer tips.
1. Early models:
a. With the thick plate facing the hammer bank, engage the bottom edge
of the hammer bank cover assembly on the alignment pins. Engage
the round hole first, then the oblong hole, to ensure that the cover lies
flat on the hammer bank.
b. Gently lower the hammer bank cover assembly until it lies flush on
the hammer bank.
c. Check that the hammer bank cover assembly is properly positioned
over the alignment pins and hammer tips.
2. Later models:
a. Position the hammer bank cover on the alignment pins on the
hammer bank. Make sure the hammer bank cover is properly
positioned over the alignment pins and hammer tips and lies flat on
the hammer bank.
b. Install all 12 hold-down screws finger tight. Using a Torx T-10 driver,
torque the 12 hold-screws to 14 inch-pounds (1.58 Nm) in the
sequence shown in Figure 32 on page 202.
c. With the seam of the folded lower edge of the ribbon mask facing
inward (toward the hammer bank cover), position the ribbon mask on
the alignment pins on the hammer bank cover. The ribbon mask is
correctly installed when the angled ends of the ribbon mask match
the angled ends of the hammer bank cover. Install the three clamp
plates and six screws finger tight. Using a Torx T-10 driver, torque the
six screws to 14 inch-pounds (1.58 Nm) in the sequence shown in
Figure 32 on page 202.
3. Install the shuttle frame assembly (page 242).
4. Return the printer to normal operation (page 153).
202
Chapter 7 Section I: Replacement Procedures
Figure 32. Hammer Bank Cover Assembly / Ribbon Mask
1
2
3
4
5
6
7
8
9
10
11
12
1 2 3 5 4 6
Early Models
Later Models
Hammer Bank Cover
(Thick Plate)
Ribbon Mask Torque Sequence
Hammer Bank Cover Torque Sequence
Ribbon Mask
(Thin Plate)
Hammer Bank Cover
Assembly
Ribbon Mask
Clamp Plate (3)
Hammer Bank Cover
Screw (6)
Screw (12)
Cover Assembly, Shuttle
203
Cover Assembly, Shuttle
Removal
1. Prepare the printer for maintenance (page 152).
2. Loosen the shuttle cover screws (page 258, Figure 44, item 2).
3. Grasping the edges of the shuttle cover assembly, tilt up the rear edge
and lift the shuttle cover assembly out of the printer.
Installation
1. Place the shuttle cover assembly in the printer. Tilt the forward edge of
the cover down slightly and work the cover into position (page 258, Figure
44).
NOTE: Make sure the holes in the cover are over the locating pins.
2. Tighten the shuttle cover screws (page 258, Figure 44, item 2).
3. Return the printer to normal operation (page 153).
204
Chapter 7 Section I: Replacement Procedures
Cover Assembly, Top, Pedestal Model
Removal
1. Prepare the printer for maintenance (page 152).
2. Remove the operator panel (page 228).
3. Remove five screws and the control panel bracket. (See Figure 43, page
256, items 3 and 4.)
4. Loosen the two captive #2 Phillips screws in the lower front corners of the
top cover. (See Figure 43, page 256, item 14.)
5. Loosen, but do not remove, the two #2 Phillips hold-down screws on the
rear of the printer. (See Figure 43, page 256, item 8.)
6. Lift the top cover assembly off the printer base.
Installation
1. To install the top cover assembly, reverse steps 2 through 6 of the
removal procedure.
2. Return the printer to normal operation (page 153).
Dashpot
205
Dashpot
This procedure applies only to cabinet models.
Removal
1. Prepare the printer for maintenance (page 152).
2. Open the printer cover.
3. Open the floor cabinet rear door.
4. Pry back the spring retaining clips (page 254, Figure 42).
5. Remove the dashpot from the ball studs.
Installation
ATTENTION
The dashpot must be installed with the large cylinder uppermost.
1. Position the dashpot against the ball studs on the upper and lower
brackets (page 254, Figure 42). The large cylinder must be uppermost.
2. Push the dashpot onto the ball joints and install the spring clips.
3. Close the printer cover. If necessary, adjust the position of the ball joint
stud in the lower bracket to achieve smooth and complete closure.
4. Return the printer to normal operation (page 153).
<3> Two persons may be required to do this procedure. Prop or
hold the top cover securely open while disengaging the
dashpot.
CAUTION
206
Chapter 7 Section I: Replacement Procedures
Doors, Cabinet, Reversing
NOTE: Floor cabinet printers are assembled with the front door hinged on the
left side so that it opens at the right side. The rear door is hinged on
the right side so that it opens on the left side. This procedure enables
you to reverse this door configuration.
1. Open the front and rear cabinet doors.
2. Mark the top of each door.
3. Remove the screws and wire ropes from the doors and cabinet frame.
(See Figure 40, page 250, item 9.)
4. Lift each door up and off the hinge pins of the upper and lower cabinet
hinge plates. Do not remove the hinge plates from the doors.
5. Remove two screws and the paper fence from the original rear door.
6. Remove the screws securing the hinge pin plates to the front and rear of
the cabinet. Remove the hinge plates and the pads beneath the plates.
7. Install pads and hinge pin plates to the right front side of the frame, with
the hinge pins up and toward the outside edge of the printer frame.
8. Install pads and hinge pin plates to the left rear side of the frame, with the
hinge pins up and toward the outside edge of the printer frame.
9. Move the original rear door to the front of the printer. With the marked top
uppermost, slide the door hinges down onto the hinge pins. Adjust the
position of the hinge pin plates as necessary so the door closes squarely
against the frame.
10. Move the original front door to the rear of the printer. With the marked top
uppermost, slide the door hinges down onto the hinge pins. Adjust the
position of the hinge pin plates as necessary so the door closes squarely
against the frame.
11. Install the paper fence to the new rear door with the two screws.
12. Install the wire ropes to the doors and the cabinet frame.
Ethernet Interface Assemblies
207
Ethernet Interface Assemblies
NOTE: The Ethernet LAN option is available in one of three configurations:
10Base-T, 10Base2, or 10/100Base-T. These options are available
factory installed or as field kits. Removal and installation is the same
for all versions. The functions of the LEDs and DIP switches on the
various Ethernet interface boards are described on page 52 and page
54.
To convert an Ethernet-equipped printer to a parallel interface,
remove the Ethernet board assembly and install the Centronics
connector in the slot the Ethernet board occupied. The Centronics
cable joins the back of the Ethernet board to the controller board.
Removal
ATTENTION
To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling circuit boards, the
shuttle frame assembly, and any other electronic component.
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Disconnect Centronics cable connector P112 from connector J112 on the
CMX controller board. (See Figure 47, page 264.)
4. Open the ferrite clamp and lift the Centronics cable out of the ferrite
clamp.
5. Loosen the two screws securing the Ethernet interface assembly to the
cutout at the rear of the card cage.
6. Slide the Ethernet interface assembly out of the cutout in the card cage
and lift the assembly out of the card cage.
Installation
ATTENTION
To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling circuit boards, the
shuttle frame assembly, and any other electronic component.
1. Reverse steps 2 through 6 of the removal procedure.
2. Initialize the Ethernet interface (page 183).
3. Return the printer to normal operation (page 153).
208
Chapter 7 Section I: Replacement Procedures
Fan Assembly, Cabinet Exhaust
Removal
1. Prepare the printer for maintenance (page 152).
2. Open the floor cabinet doors and the printer cover.
3. Remove the paper stacker. (See Figure 41, page 252.)
4. Remove the three screws securing the air exhaust duct. (The top screw is
located near the right front of the card cage, in front of the square air
holes in the printer base plate.) (See Figure 42, page 254.)
5. Disconnect the fan cable connector from connector P307 and remove the
air exhaust duct.
6. Remove the fan cable connector from the cutout in the side of the air
exhaust duct.
7. Remove the two fan mounting screws and the cabinet exhaust fan
assembly.
Installation
ATTENTION
Make sure to install the fan so that air flow is down.
1. Position the cabinet exhaust fan assembly in the air exhaust duct so that
air flow is down, and install the two screws securing the fan to the duct.
(See Figure 42, page 254.)
2. Snap the fan cable connector into the cutout in the side of the air exhaust
duct.
3. Move the air exhaust duct back into position and install the three screws.
4. Connect the cabinet exhaust fan cable connector to connector P307.
5. Install the paper stacker. (See Figure 41, page 252.)
6. Return the printer to normal operation (page 153).
Fan Assembly, Card Cage
209
Fan Assembly, Card Cage
Removal
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Disconnect the fan cable connector:
Cabinet Model, Figure 52, page 278.
Pedestal Model, Figure 46, page 262.
4. Cabinet Model: Remove the two fan mounting screws from the bottom of
the fan. (See Figure 52, page 278, item 2.)
Pedestal Model: Remove the four fan mounting screws and nut. (See
Figure 46, page 262, items 1 through 4.)
5. Remove the card cage fan assembly from the card cage.
6. Remove the screw securing the shield to the card cage fan.
Installation
ATTENTION
Make sure to install the fan so the label faces toward the inside of the
printer. Air flow is INTO the card cage.
1. Reverse steps 2 through 6 of the removal procedure.
2. Return the printer to normal operation (page 153).
210
Chapter 7 Section I: Replacement Procedures
Fan Assembly, Hammer Bank
Removal
1. Prepare the printer for maintenance (page 152).
2. Remove the shuttle cover assembly (page 203).
3. Pedestal Model: Remove the top cover assembly (page 204).
4. Trace the hammer bank fan cable assembly back to the controller board
connector J107, releasing it from all cable constraints. (See the cable
routing diagrams on page 299 and page 301.)
5. Disconnect connector P107 from the controller board and remove the fan
connector (HBF) from on the controller board. (See page 197.)
6. Remove the two screws securing the fan to the base casting. Angle the
hammer bank fan assembly up and out of the base casting and feed the
motor wires and cable connector out from between the base casting and
the base pan. (See Figure 52, page 278.)
Installation
ATTENTION
Make sure to install the fan so the label faces up. Air flow is UP.
NOTE: The hammer bank fan assembly is installed by angling it down and
under the shuttle motor.
1. Feed the hammer bank fan cable connector (HBF) and motor wires
between the fan well of the base casting and the base pan. Reach up
under the base casting and route the fan cable to the right and angle the
hammer bank fan assembly under the shuttle motor and down into the fan
well. (See Figure 52, page 278.)
2. Route the fan motor wires as shown on page 300, connect fan cable
connector (HBF) to P107, then connect P107 to J107 on the controller
board. (See page 197.)
3. Install two screws in the locations shown in Figure 52 (page 278).
4. Pedestal Model: Install the top cover assembly (page 204).
5. Install the shuttle cover assembly (page 203).
6. Return the printer to normal operation (page 153).
Hammer Spring Assembly
211
Hammer Spring Assembly
Removal
1. Prepare the printer for maintenance (page 152).
2. Remove the shuttle frame assembly (page 242).
3. Carefully vacuum the shuttle frame assembly.
4. Remove the hammer bank cover assembly (page 200).
ATTENTION
Hammer springs and hammer tips are fragile. Do not touch the hammer
springs or tips. Handle hammer springs by the thick mounting base
only. Apply pressure only to the mounting base.
NOTE: Replace a hammer spring assembly only if there is visible damage or
broken parts can be seen in the assembly.
5. Remove the mounting screws from the old hammer spring assembly.
(See Figure 33, page 212.)
6. Handling the hammer spring assembly by the mounting base only, gently
pry the old hammer spring assembly off its mounting pins. (See Figure 33,
page 212.)
7. Inspect the hammer bank and the old hammer spring assembly:
a. If there is ink on the hammer bank mounting surface, the hammer
spring assembly mounting surface, or the hammer spring neck or
tines, reinstall the old hammer spring assembly and replace the
shuttle frame assembly (page 242).
b. If the old hammer spring assembly and the hammer bank are free of
ink, install the new hammer spring assembly (page 213).
212
Chapter 7 Section I: Replacement Procedures
Figure 33. Hammer Spring Assembly, Removal
Hammer Spring
Assembly 7
Hammer Spring
Assembly 1
NOTE: The hammer spring assemblies shown here
are for 6400-004/-04P/-005/-05P printers. The
number of hammer springs and mounting screws
varies among printer models, but removal and
installation are the same.
Discard old screws.
Hammer Spring Assembly
213
Installation
NOTE: 6400-050, -P50, -010, -P10, -014, -015, -C05, and -C5P printers must
use the CMX 040 controller board.
1. Using a clean dry cloth, wipe the hammer spring mounting surface on the
hammer bank. Make sure the cloth does not leave lint on the hammer
bank.
ATTENTION
Hammer springs and hammer tips are fragile. Do not touch the hammer
springs or tips. Handle hammer springs by the thick mounting base
only. Apply pressure only to the mounting base.
NOTE: Replace a hammer spring assembly only if there is visible damage or
you see broken parts in the assembly.
2. Handling it by the mounting base only, remove the new hammer spring
assembly and mounting screws from the box.
3. Handling the hammer spring assembly by the mounting base only,
carefully position the new hammer spring assembly onto the hammer
bank mounting pins and press it into position with the flat end of the stick
supplied in the hammer spring replacement kit. (See Figure 34, page
214.)
4. Install the mounting screws from the replacement kit. Using a Torx** T-10
bit adapter, torque each screw to 14 inch-pounds (1.58 Nm). Tighten the
center screw(s) first. (See Figure 34, page 214.)
5. Install the hammer bank cover assembly (page 200).
6. Install the shuttle frame assembly (page 242).
7. Install the ribbon and load paper.
ATTENTION
Do not attempt to adjust or tweak hammer springs.
8. Run a Customer Engineer Test and check print quality (page 134):
a. If print quality is acceptable, return the printer to normal operation
(page 153).
b. If print quality is still degraded, replace the shuttle frame assembly
(page 242).
214
Chapter 7 Section I: Replacement Procedures
Figure 34. Hammer Spring Assembly, Installation
Use new screws from the
kit. Torque the screws to
14 inch-pounds (1.58
Newton-meters).
New Hammer
Spring Assembly
NOTE: The hammer spring assemblies shown here
are for 6400-004/-04P/-005/-05P printers. The
number of hammer springs and mounting screws
varies among printer models, but removal and
installation are the same.
IBM Coax/Twinax Expansion Board
215
IBM Coax/Twinax Expansion Board
Removal
ATTENTION
To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling circuit boards, the
shuttle frame assembly, and any other electronic component.
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Loosen, but do not remove, the two screws securing the coax/twinax I/O
plate to the rear of the card cage. Loosen the thumbscrew on the CT
board until the screw is released from the standoff on the controller board.
(See Figure 54, page 282.)
4. Carefully lift the expansion-CT board out of the card cage cutout and off
the expansion connector adapter that attaches the CT to the CMX board.
5. Remove the expansion connector adapter from the CMX controller board
by carefully lifting it straight up and out of the controller connector.
Installation
1. Reverse steps 2 through 5 of the removal procedure.
2. Return the printer to normal operation (page 153).
216
Chapter 7 Section I: Replacement Procedures
Magnetic Pick-up (MPU) Assembly
Removal
1. Prepare the printer for maintenance (page 152).
2. Remove the shuttle cover (page 203).
3. Disconnect the shuttle cable assembly connector (page 272, Figure 49).
4. Disconnect the magnetic pick-up (MPU) cable connector (page 272,
Figure 49).
5. Loosen the 7/64 inch hex MPU clamp screw (page 272, Figure 49).
6. Unscrew the MPU assembly from the MPU bracket.
Installation
1. Install the MPU assembly by screwing it into the MPU bracket (page 272,
Figure 49).
2. Using a feeler gauge, adjust the gap between the MPU assembly and the
flywheel to 0.010 .001 inch (0.254 0.025 mm). Torque the MPU clamp
screw to 19 1 inch-pounds (2.15 0.11 Nm).
3. Check the gap between the MPU assembly and the flywheel with a feeler
gauge:
a. If the gap is 0.010 .001 inch (0.254 0.025 mm), go to step 4.
b. If the gap is not 0.010 0.001 inch (0.254 0.025 mm), loosen the
MPU clamp screw and go back to step 2.
ATTENTION
Make sure the MPU cable is below the extension spring and does not
touch the spring after the cable is connected.
4. Connect the magnetic pick-up (MPU) cable connector.
5. Connect the shuttle cable assembly connector (page 272, Figure 49).
6. Install the shuttle cover (page 203).
7. Adjust the hammer phasing (page 173).
8. Return the printer to normal operation (page 153).
Memory and Security Modules
217
Memory and Security Modules
Removal
1. Make a configuration printout of all configurations. (Refer to the Setup
Guide.)
2. Prepare the printer for maintenance (page 152).
3. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
ATTENTION
To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling circuit boards, the
shuttle frame assembly, and any other electronic component.
NOTE: If flash SIMMs are removed from one controller board and placed on
another controller board, the SIMMs must be placed on the new
board in the same order and location as on the original board.
4. Gently pry the side locks open, angle the SIMM toward the front of the
printer, and remove the SIMM from the socket. (See Figure 35, page 220
for the locations of memory modules.)
5. Using a module extraction tool, remove the security module. (See Figure
35, page 220.)
218
Chapter 7 Section I: Replacement Procedures
Installation
ATTENTION
To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling circuit boards, the
shuttle frame assembly, and any other electronic component.
NOTE: Flash SIMMs from one CMX controller board must be placed in the
same slot on a replacement CMX controller board. Installing flash
memory from one controller board to another does not transfer all
operating system software, so you must download the emulation
again.
NOTE: Part numbers for pre-written flash memory and security modules are
listed in Table 8 and Table 9.
1. Insert the memory module into the correct socket on the CMX controller
board:
a. Position the SIMM so the notched end is toward the right-hand side of
board. (See Figure 35, page 220.)
b. Press the SIMM into the socket with the top of the SIMM angled away
from the center of the board. When the SIMM is seated in the socket,
gently push on the ends until it locks in the upright position.
2. Install the security module. (See Figure 35, page 220.)
3. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
4. Download the emulation (page 176).
5. Return the printer to normal operation (page 153).
6. Using the configuration printouts you made as step 1 of the removal
procedure, reset and save the printer configurations. (Refer to the Setup
Guide.)
Memory and Security Modules
219
Table 8. Pre-Written Flash SIMMs and Security Modules: Early Models
Code Load Description
Pre-Written Flash for models
004, 04P, 005, 05P, 008, 08P,
009, 09P, 012, 014, C05, C5P
Security Module
IBM P/N (Vendor P/N)
Base ASCII 24H9315 14H5509 (154143-002)
ASCII with IGP 24H9317 14H5490 (154143-001)
ASCII with Code V 24H9329 14H5490 (154143-001)
Base CTA 24H9332 14H5509 154143-002)
CTA with IGP 24H9330 14H5490 (154143-001)
CTA with Code V 24H9331 14H5490 (154143-001)
IPDS Twinax 24H9333 14H5509 (154143-002)
IPDS Twinax with IGP 24H9334 14H5490 (154143-001)
IPDS Twinax with Code V 24H9335 14H5490 (154143-001)
IPDS Coax 24H9336 14H5509 (154143-002)
IPDS Coax with IGP 24H9337 14H5490 (154143-001)
IPDS Coax with Code V 24H9338 14H5490 (154143-001)
LQ-1600K (Hanzi) 24L5211 38L0821 (154143-005)
Table 9. Pre-Written Flash SIMMs and Security Modules: Later Models
Code Load Description
Pre-Written Flash for models
050, P50, 010, P10, 015
Security Module
IBM P/N (Vendor P/N)
Base ASCII 02N8319 14H5509 (154143-002)
ASCII + CV/IGP 02N8320 14H5490 (154143-001)
Ethernet IPDS for ASCII 02N8321 14H5509 (154143-002)
Ethernet IPDS + CV/IGP
for ASCII
02N8322 14H5490 (154143-001)
Base CTA 02N8323 14H5509 (154143-002)
Base CTA + CV/IGP 02N8324 14H5490 (154143-001)
Coax/Twinax (Ethernet)
IPDS
02N8325 14H5509 (154143-002)
Coax/Twinax (Ethernet)
IPDS + CV/IGP
02N8326 14H5490 (154143-001)
220
Chapter 7 Section I: Replacement Procedures
Figure 35. Memory and Security Modules
2
1
3
Bank 0
Bank 1
Bank 0
Bank 1
80-pin SIMM
J11 = Bank 0 (must always
be filled)
J10 = Bank 1
Reserved for upgrades
If 1 Flash SIMM, use Bank 0
If 2 Flash SIMMs, use both
banks but put pre-programmed
SIMMs in J11
72-pin SIMM
J16 = Bank 0 (must always
be filled)
J15 = Bank 1
Reserved for upgrades
If 1 DRAM SIMM, use Bank 0
If 2 DRAM SIMMs, use both
banks (It does not matter which
SIMM goes into which bank
IMPORTANT:
J11 and J16 must always be filled, no matter what
combination of SIMMs is used. The CMX
board does not support EDO RAM.
CMX Controller Board
Security PAL*
Notched End
DRAM: Flash:
Datastream ASCII
ASCII
IGP
Code V
CTA
CTA
IGP
Code V
IPDS
CTA
IPDS
CTA
IGP
Code V
LQ-1600K
(Hanzi)
Flash
Memory
8 MB 8 MB 8 MB 8 MB 8 MB 8 MB 4 MB
DRAM 8 MB 8 MB 8 MB 8 MB 8 MB 8 MB 8 MB
CT Installed No No Yes Yes Yes Yes No
Security PAL
Vendor P/N
154143-002
(14H5509)
154143-001
(14H5490)
154143-002
(14H5509)
154143-001
(14H5490)
154143-002
(14H5509)
154143-001
(14H5490)
154143-005
(38L0821)
Notch
Latch
Latch
Blank SIMMs:
4 MB Flash - 24H9009
4 MB DRAM - 14H5508
8 MB DRAM - 24H9010
* Security Module, Base: 14H5509
Security Module, Graphics: 14H5490
CAUTION: <5> Do not remove or replace
the NVRAM. The NVRAM contains a
lithium battery that can explode if it is
replaced incorrectly. NVRAM is replaced
only at the factory.
Motor Assembly, Paper Feed
221
Motor Assembly, Paper Feed
Removal
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Cabinet Model: Loosen four screws and remove the barrier shield. (See
Figure 44, page 258, items 3 and 4.)
Pedestal Model: Remove the four screws, the barrier shield, and the
paper guide. (See Figure 45, page 260, items 3, 4, and 5.)
4. Remove the timing belt cover by squeezing the top and bottom to release
the plastic tabs from the slots in the side plate (page 258, Figure 44).
5. Loosen the paper feed motor mount screws (page 278, Figure 52, item
10).
6. Loosen the shaft collar setscrew and remove the paper feed motor pulley,
shaft collar, and paper feed timing belt (page 278, Figure 52).
7. Trace the paper feed motor cables back to the controller board, releasing
it from tie wraps. (See the cable routing diagrams on page 300 and page
302.)
8. Disconnect connector P107 from the controller board and remove the
paper feed motor connector from connector P107. (See page 195.)
NOTE: Some paper feed motors are mounted with nuts and bolts; other
motors have threaded flanges, eliminating the need for nuts.
9. Remove the motor mount bolts (and nuts, if present).
10. Remove the paper feed motor assembly.
222
Chapter 7 Section I: Replacement Procedures
Installation
1. Position the paper feed motor assembly on the right side plate and install
the motor mount bolts and nuts finger tight (page 278, Figure 52).
2. Connect the paper feed motor cable connector to connector P107, then
connect P107 to J107 on the controller board. (See page 195.)
3. Install the collar, paper feed motor pulley, and timing belt.
4. Align the paper feed motor pulley with the splined shaft pulley.
ATTENTION
Make sure there is at least 0.040 inches (1.016 mm) of clearance
between the collar/pulley and the motor face plate.
5. Hold the collar snug against the motor pulley and torque the setscrew to
25 2 inch-pounds (2.82 0.23 Nm).
6. Using the straight end of a force gauge, apply 12 pounds (53.4 N) of
pressure to the paper feed motor. Use the splined shaft to steady the
gauge.
7. Reduce pressure to 9 pounds (40.0 N) and torque the motor mount
screws to 18 2 inch-pounds (1.36 0.23 Nm).
8. Snap the timing belt cover into the slots in the side plate.
9. Cabinet Model: Install the barrier shield and four screws. (See Figure 44,
page 258, items 3and 4.)
Pedestal Model: Install the barrier shield, paper guide, and four screws.
(See Figure 45, page 260, items 3, 4, and 5.)
10. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
11. Return the printer to normal operation (page 153).
Motor Assembly, Platen Open
223
Motor Assembly, Platen Open
Removal
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Cabinet Model: Remove the card cage fan (page 209).
4. Remove the platen open belt cover by squeezing the top and bottom to
release the plastic tabs from the slots in the side plate (page 276, Figure
51).
5. Loosen the two 5/16 inch motor mount screws (page 278, Figure 52).
6. Loosen the 1/16 hex pulley setscrew and remove the motor pulley and
platen open belt.
7. Trace the platen open motor cables back to the controller board,
releasing the cables from the tie wraps. (See cable routing diagrams on
page 300 and page 302.)
8. Disconnect connector P106 from the controller board.
9. Trace the platen open motor cables to the connector shell and remove the
platen open cable connector from the connector shell (page 195).
NOTE: Some platen open motors are mounted with nuts and bolts; other
motors have threaded flanges, eliminating the need for nuts.
10. Remove the two 5/16 inch motor mount screws (and nuts, if present).
11. Remove the platen open motor assembly.
224
Chapter 7 Section I: Replacement Procedures
Installation
1. Position the platen open motor assembly with the wires toward the rear
(page 278, Figure 52).
2. Install the two 5/16 inch motor mount screws (and nuts, if present) finger
tight.
3. Install the platen open belt and motor pulley. Bottom out the motor pulley
on the motor shaft and tighten the setscrew to 9 2 inch-pounds (1.24
0.23 Nm).
4. Connect the platen motor cable connector to connector shell P106.
5. Connect shell connector P106 to J106 on the controller board. Install tie
wraps to secure the motor cable. (See cable routing diagrams on page
300 and page 302.)
6. Close the forms thickness lever all the way.
ATTENTION
Too much tension on the platen open belt can cause the platen gap to
change, which can lead to premature wear of the platen, damaged
hammer tips, and poor print quality.
7. Using a force gauge, apply 10 pounds (44.48 N) of tension to the platen
open motor shaft by pushing away from the large platen pulley, reduce
tension to 5 pounds (22.24 N) and torque the motor mount screws to
11 2 inch-pounds (1.24 0.23 Nm).
8. Snap the platen open belt cover into the slots in the side plate.
9. Cabinet Model: Install the card cage fan (page 209).
10. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
11. Return the printer to normal operation (page 153).
Motor Assembly, Ribbon Drive
225
Motor Assembly, Ribbon Drive
Removal
1. Prepare the printer for maintenance (page 152).
2. Remove the ribbon hub (page 238).
3. Remove two screws and washers securing the ribbon drive motor to the
base casting (page 278, Figure 52).
4. Lift and rotate the ribbon drive motor until the motor cable is aligned with
the slot on the base casting.
5. Disconnect the ribbon drive motor cable connector.
6. Cabinet models: remove the heat boot from the motor. You will install the
boot on the replacement motor.
Installation
1. Reverse steps 2 through 6 of the removal procedure above.
NOTE: The ribbon drive motor should be secured at the right front and left
rear corners. (See page 278, Figure 52.)
2. Return the printer to normal operation (page 153).
226
Chapter 7 Section I: Replacement Procedures
Network Print Server
Installation and operation of this optional feature are described in the Print
Server Users Guide, P/N 30H4056. This guide describes error messages and
troubleshooting information. Also provided is a section that describes IBM
service procedures.
Removal
ATTENTION
To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling circuit boards, the
shuttle frame assembly, and any other electronic component.
1. Prepare the printer for maintenance (page 152).
2. Refer to the Print Server Users Guide (P/N 30H4056) for information on
determining if the print server is operating correctly.
Installation
1. Refer to the Print Server Users Guide (P/N 30H4056) for information on
installing and testing the feature.
2. Return the printer to normal operation (page 153).
Operator Panel Assembly, Cabinet Model
227
Operator Panel Assembly, Cabinet Model
Removal
1. Prepare the printer for maintenance (page 152).
2. Open the printer cover.
3. Remove the four screws securing the operator panel plate to the panel
bracket. (See Figure 42, page 254.)
4. Press down on the plastic tab at the upper rear of the panel and slide the
operator panel downward on the mounting plate until the tabs on the
panel housing slide out of the cutouts.
5. Lift the operator panel assembly and disconnect the phone-style cable
connector.
Installation
1. Connect the phone-style operator panel cable to the bottom of the
operator panel. (See Figure 42, page 254.)
2. Position the operator panel over the cutouts in the panel plate. Slide the
panel upward until the plastic tab at the upper rear of the panel locks into
the mounting plate.
3. Position the operator panel and plate on the bracket and install the four
screws finger tight. (See Figure 42, page 254.)
4. Slowly lower the printer cover and align the operator panel in the cover
cutout. Open the printer cover and tighten the panel plate screws.
5. Return the printer to normal operation (page 153).
228
Chapter 7 Section I: Replacement Procedures
Operator Panel Assembly, Pedestal Model
Removal
1. Prepare the printer for maintenance (page 152).
2. Open the printer cover.
3. Tilt the operator panel toward the front of the printer.
4. Disconnect the phone-style cable connector at the rear of the operator
panel.
5. Press down on the plastic tab at the upper rear of the panel and slide the
operator panel downward on the mounting plate until the tabs on the
panel housing slide out of the cutouts.
Installation
1. Tilt the operator panel mounting plate toward the front of the printer.
2. Position the operator panel over the cutouts in the mounting plate and
slide the panel upward until the plastic tab at the upper rear of the panel
locks into the mounting plate.
3. Connect the phone-style operator panel cable to the bottom of the
operator panel.
4. Close the printer cover.
5. Return the printer to normal operation (page 153).
Paper Guide Assembly
229
Paper Guide Assembly
This procedure applies only to cabinet models.
Removal
1. Prepare the printer for maintenance (page 152).
2. Open the printer cover.
3. Loosen the three paper guide assembly hold-down screws (page 258,
Figure 44, item 6).
4. Slide the paper guide assembly to the left and lift it off the card cage.
Installation
1. Position the paper guide assembly offset slightly to the left on the card
cage with the keyway cutouts over the three loosened hold-down screws
(page 258, Figure 44, item 6).
2. Slide the paper guide assembly to the right, engaging the three hold-
down screws in the keyway slots. Slide the paper guide assembly to the
right as far as it will go.
3. Tighten the three hold-down screws (page 258, Figure 44, item 6).
4. Return the printer to normal operation (page 153).
230
Chapter 7 Section I: Replacement Procedures
Paper Ironer
Removal
1. Remove the shuttle frame assembly (page 242).
2. Move the forms thickness lever to the open position.
3. Push the ends of the paper ironer toward the rear of the printer,
disengage the tabs, then lift it up and out (page 276, Figure 51).
Installation
NOTE: The black tape on the paper ironer faces the paper detector switch
assembly.
1. Position the paper ironer so that the black tape is on the side that faces
the paper detector switch assembly. (See page 276, Figure 51.)
2. Push the paper ironer down into the slots until the tabs engage.
3. Install the shuttle frame assembly (page 242).
4. Return the printer to normal operation (page 153).
<2> Over time the upper edge of the paper ironer can become
sharp. To avoid cutting yourself, handle the paper ironer on
the sides.
CAUTION
Platen
231
Platen
Removal
1. Prepare the printer for maintenance (page 152).
2. Remove the shuttle frame assembly (page 242).
3. Remove the paper ironer (page 230).
4. Remove the three 1/4 inch screws securing the paper ironer bracket
assembly and remove the assembly. (See Figure 51, page 276, items 4
through 6.)
5. Remove the platen open belt (page 189).
6. Remove the platen pulley (page 276, Figure 51, item 21):
a. Loosen the 7/64 inch collar clamp screw.
b. Pull the platen pulley off the platen shaft.
7. Pull the spring link and white plastic bushing off the platen shaft and
remove the spring link, bushing, and spring. (See Figure 51, page 276,
items 16, 17, and 18.)
8. Remove the forms thickness lever by loosening the 7/64 inch clamp
screw and pulling the lever off the platen shaft. (See Figure 51, page 276,
item 15.)
9. Remove the right side platen support spring by repeating step 7 on the
right side of the platen.
10. Remove the Phillips #1 screw and washer securing the forms thickness
indicator plate from the inside of the right side bracket. (See Figure 51,
page 276, items 9 and 10.)
11. Pull the indicator plate, with the interlock switch assembly attached, off
the platen shaft.
12. Remove the two 7/32 inch screws and washers securing the right ribbon
guide assembly to the side plate. (See Figure 52, page 278, item 11, 13,
and 14.)
13. Slide the ribbon guide assembly out of the side plate.
14. Pull the right side of the platen toward the front of the printer and move
the platen to the right and out of the left side plate. (Hold the black metal
washer on the left side shaft as you remove the platen. Make sure the
copper wear saddles in the platen seat of the mechanism base stay in
place.)
232
Chapter 7 Section I: Replacement Procedures
Installation
IMPORTANT
The dowel pins protruding from the ends of the platen are the platen
shafts, and are not equal in length. The platen must be installed with the
longer shaft on the right side.
1. Wipe the platen shafts clean of grease and debris.
2. Install two washers on the longer (right) platen shaft. (See Figure 36.)
3. Apply bearing lubricant to both platen shafts.
Figure 36. Installing the Platen Adjust Bracket
4. Make sure the two wear saddles are set flush into the corners of the
mechanism base platen seat. (See Figure 37.)
5. Apply a layer of bearing lubricant 1/4 inch high to the seat of each wear
saddle, making the layer as wide as the saddle and touching the rear
angled surface.
6. Install one platen adjust bracket onto the longer platen shaft, with the
screw at the top of the bracket.
7. Place the other bracket onto the left side mechanism base platen seat so
that the mechanism base platen seat is between the flanges of the
bracket.
8. Insert the shorter platen shaft through the left adjust bracket and through
the opening in the left side plate. Rotate the longer shaft into the opening
in the right side plate and position the adjustment brackets as shown in
Figure 36.
Platen Shaft
(Right Side)
Washer
Washer
Ironer Bracket
Platen Adjust
Bracket
Platen
233
Figure 37. Positioning the Platen Adjust Brackets
9. Slide the right ribbon guide assembly into the side plate and install the
two 7/32 inch screws and washers. (See Figure 52, page 278, items 11,
13 and 14.)
10. Install the forms thickness indicator plate:
a. Slide the indicator plate, with the interlock switch assembly attached,
onto the platen shaft and up against the right side plate.
b. Install the Phillips #1 screw and washer securing the indicator plate.
11. Install the black metal washer onto the left side of the platen shaft. (See
Figure 51, page 276, item 26.)
12. Apply bearing lubricant to the nylon bearings in the two spring links, slide
the spring links onto the two platen shafts, and connect the springs to the
spring hooks in the side plates. (See Figure 51, page 276, items 16, 17,
and 18.)
13. Apply bearing lubricant to the two platen shafts on both sides, between
the ends of the platen and the platen adjustment brackets.
14. Install the paper ironer bracket. (See Figure 36, page 232):
a. With the flat part of the bracket facing the front of the printer, place
the two hooks of the upper part of the paper ironer over the platen
shafts.
The left hook of the paper ironer goes between the left platen
adjustment bracket and the platen.
Platen Adjust
Bracket
Washers
Platen
Wear
Saddle
Mechanism
Base Platen
Seat
234
Chapter 7 Section I: Replacement Procedures
For the right side of the platen, a washer goes on both sides of the
paper ironer hook and the hook goes to the left of the right platen
adjustment bracket. (See Figure 36, page 232.)
b. Install and torque three screws to 20 2 inch-pounds (2.26 0.23
Nm).
15. Push the platen to the left.
16. Install the forms thickness lever onto the right side platen shaft, pressing
the interlock switch out of the way as the lever slides past it. Tighten the
7/64 inch setscrew. (See Figure 51, page 276.) Open and close the forms
thickness lever to make sure the setscrew does not touch the right ribbon
guide.
17. Install the platen shaft pulley with the 7/64 inch setscrew facing up and
tighten the setscrew. Open and close the forms thickness lever and check
that the platen pulley setscrew does not hit the left ribbon guide.
18. Install, but do not adjust, the platen open belt and platen open motor
pulley (page 189).
19. Install the paper ironer with the black tape towards the rear of the printer
(page 230).
20. Install the shuttle frame assembly (page 242).
21. Adjust the platen gap (page 162).
22. Adjust the platen open belt (page 156).
23. Check ribbon guide alignment (page 166).
24. Check the hammer phasing (page 173).
25. Return the printer to normal operation (page 153).
Resistors, Terminating
235
Resistors, Terminating
For parallel interface configurations, the printer is equipped with 470 ohm pull-
up terminating resistors and 1K ohm pull-down terminating resistors on the
controller board. These are suitable for most applications. (See Figure 38,
page 236.)
If the standard terminating resistor pack is not compatible with the interface
driver requirements of the host computer, other values of pull-up and pull-
down resistors may be required. 220 ohm pull-up and 330 ohm pull-down
alternate terminating resistors are provided with the printer. If you install the
220 ohm pull-up resistor, you must also install the 330 ohm pull-down resistor.
Possible terminating resistor combinations are shown below.
Removal
ATTENTION
To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling circuit boards, the
shuttle frame assembly, and any other electronic component.
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Locate the terminating resistor packs. (See Figure 38, page 236.)
4. Using a chip puller, remove the packs.
Installation
ATTENTION
To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling circuit boards, the
shuttle frame assembly, and any other electronic component.
1. Using a chip installation tool, install the resistor packs in the correct
socket. (See Figure 38, page 236.)
2. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
3. Return the printer to normal operation (page 153).
Configuration RP1 (Pull-Up) RP2 (Pull-Down)
Factory Default 470 Ohm 1K Ohm
Alternate 1 220 Ohm 330 Ohm
Alternate 2 1K Ohm None
236
Chapter 7 Section I: Replacement Procedures
Figure 38. Terminating Resistors, Removal/Installation
Default: 470 Ohm
Alt 1: 220 Ohm
Alt 2: 1K Ohm
Default: 1K Ohm
Alt 1: 330 Ohm
Alt 2: None
RP1
RP2
CMX Controller Board
Resistor Kit: 14H5525
Ribbon Guide Assembly (L/R)
237
Ribbon Guide Assembly (L/R)
Removal
1. Prepare the printer for maintenance (page 152).
NOTE: The right ribbon guide is shown in Figure 52. The removal procedure
is the same for the left ribbon guide.
2. Cut and remove the tie wrap from the tie wrap hole to free the ribbon
guide cable (page 278, Figure 52).
3. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
4. Trace the ribbon guide cable back to the controller board, releasing it from
the cable restraints. (See cable routing diagrams on page 300 and page
302.)
5. For the left ribbon guide, disconnect connector shell P106 from the
controller board. For the right ribbon cable, disconnect connector shell
P107 from the controller board.
6. Trace the ribbon guide wires to the connector shell, and remove the cable
connector from the connector shell (page 195).
7. Remove the two screws and washers securing the ribbon guide assembly
to the side plate.
8. Slide the ribbon guide assembly out of the side plate.
Installation
NOTE: The right ribbon guide is shown in Figure 52. The installation
procedure is the same for the left ribbon guide.
1. Reverse steps 2 through 8 of the removal procedure above.
2. Align the ribbon guides (page 166).
3. Return the printer to normal operation (page 153).
238
Chapter 7 Section I: Replacement Procedures
Ribbon Hub
Removal
1. Prepare the printer for maintenance (page 152).
2. Loosen the Torx T-10 screw in the ribbon spool hub (page 278, Figure
52).
3. Remove the hub from the shaft of the ribbon drive motor.
Installation
1. Install the ribbon spool hub over the motor shaft (page 278, Figure 52).
ATTENTION
Tightening the hub screw too much can crack the ribbon hub. Be careful
not to over-tighten the hub screw.
2. Tighten the Torx T-10 hub screw so that it contacts the flat section of the
motor shaft. Make sure the ribbon hub is securely fastened to the motor
shaft and there are no cracks in the ribbon hub around the hub screw.
3. Return the printer to normal operation (page 153).
Shaft, Splined
239
Shaft, Splined
Removal
1. Prepare the printer for maintenance (page 152).
2. Open the printer cover.
3. Remove the paper supports from the splined shaft and support shaft.
(See Figure 50, page 274, item 21.)
4. Remove the paper feed timing belt (page 188).
5. Remove the ground clip (page 274, Figure 50).
6. With grip ring pliers, remove the grip ring from left side of the splined
shaft.
7. Pull the bearing and spring link with the spring off the left side of the
splined shaft.
8. Unlock the left and right tractors and slide them to the center of the shaft.
9. Remove the bearing clamp on the right side of the splined shaft.
10. Hold the tractors so they do not fall, grasp the vertical adjustment knob,
and slide the splined shaft to the right out of the side plates and the
tractors.
240
Chapter 7 Section I: Replacement Procedures
Installation
1. Open the doors on the left and right tractors. Position the tractor belts so
the alignment marks are at the top on both tractors. (See Figure 39.)
2. Grasp the vertical adjustment knob and slide the splined shaft through the
right side plate, the tractors, and the left side plate (page 274, Figure 50).
Make sure the same spline passes the marked groove on each tractor.
3. Install the bearing clamp and screw.
4. Apply a thin film of bearing lubricant to the bearing.
5. Slide the spring link and bearing onto the left side of the splined shaft with
the white nylon bushing flange to the outside of the printer.
6. Attach the spring to the left side plate and the spring link.
7. Install the grip ring on the splined shaft with 0.010 inches of clearance
between the grip ring and the nylon bearing.
8. Install the ground clip and screw.
9. Install the paper feed timing belt (page 188).
10. Set the paper feed timing belt tension (page 154).
11. Adjust splined shaft skew (page 168).
12. Install the paper supports on the splined shaft and support shaft. (See
Figure 50, page 274, item 21.)
13. Return the printer to normal operation (page 153).
Figure 39. Splined Shaft and Tractor Installation
Splined Shaft
NOTE: Align the marks on
each tractor before inserting
the splined shaft.
Tractor
Alignment Mark
Shaft, Support
241
Shaft, Support
Removal
1. Prepare the printer for maintenance (page 152).
2. Open the printer cover.
3. Unlock the tractors and slide them to the far right.
4. Remove the paper supports from the splined shaft and support shaft.
(See Figure 50, page 274, item 21.)
5. Remove the E-ring (page 274, Figure 50).
ATTENTION
Hold the tractors while removing the support shaft, and be careful not to
lose the curved spring washers. (See Figure 50, page 274, item 5.)
6. Slide the support shaft assemblyconsisting of the support shaft, two
curved washers, bushing, horizontal adjustment knob, washer and
screwto the left, out of the tractors and the left side plate.
Installation
1. Slide the support shaft assemblyconsisting of the support shaft, two
curved washers, bushing, horizontal adjustment knob, washer, and
screwinto the left side plate. (See Figure 50, page 274.)
2. Slide the tractors onto the support shaft.
3. Slide the support shaft assembly through the right side plate.
4. While pushing on the knob to compress the curved washers, install the
E-ring in the groove on the bushing.
5. Install the paper supports on the splined shaft and support shaft. (See
Figure 50, page 274, item 21.)
6. Return the printer to normal operation (page 153).
242
Chapter 7 Section I: Replacement Procedures
Shuttle Frame Assembly
Removal
1. Prepare the printer for maintenance (page 152).
2. Remove the shuttle cover assembly (page 203).
3. Disconnect the MPU cable connector (page 272, Figure 49).
ATTENTION
To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling circuit boards, the
shuttle frame assembly, and any other electronic component.
4. Disconnect the shuttle motor cable connector (page 272, Figure 49).
5. Disconnect the hammer drive and hammer logic cables connectors from
the terminator board on the shuttle frame assembly.
6. Loosen the side 5/32 inch socket head clamp screws and pull the clamps
back and off the guide shaft. Do not remove the clamps.
7. Loosen the center 5/32 inch socket head screw enough to release the
shuttle frame assembly from the base casting.
8. Unlock and slide the tractors outward as far as they will go on the tractor
support shaft.
9. Grasping the support legs cast on both sides of the shuttle motor, lift the
shuttle frame assembly out of the base casting. Lift it slowly and
carefully: the shuttle frame assembly is heavy.
Shuttle Frame Assembly
243
Installation
1. Install the hammer bank / ribbon mask cover assembly (page 200), if it
was removed.
ATTENTION
To prevent electrostatic damage to electronic components, wear a
properly grounded static wrist strap when handling circuit boards, the
shuttle frame assembly, and any other electronic component.
Do not remove the grease from the shaft of the replacement shuttle
frame assembly. The shuttle shaft is aluminum, and the clamped ends of
the shaft must be greased to prevent galling.
2. Holding the shuttle frame assembly by the support legs cast on both sides
of the shuttle motor, set it into the base casting. Use both hands: the
shuttle frame assembly is heavy (page 264, Figure 47).
3. Align the center 5/32 inch socket head screw in the base casting and
hand turn the screw until only two or three threads have started.
4. Pull the shuttle frame assembly toward the front of the printer and hold it
in this position while you do step the next step.
IMPORTANT
Do not over tighten the shuttle frame assembly hold-down screws.
5. Slide the side clamps over the guide shaft and torque the 5/32 inch socket
head clamp screws to 20 2 inch-pounds (2.26 0.23 Nm).
6. Torque the center captive 5/32 inch socket head screw to
20 2 inch-pounds (2.26 0.23 Nm).
7. Connect the hammer drive and hammer logic cable connectors to the
terminator board on the shuttle frame assembly.
8. Connect the shuttle motor cable connector.
9. Route the MPU cable under the extension spring and connect the MPU
cable connector. (See Figure 49, page 272, item 4.) Make sure the MPU
cable does not touch the extension spring after it is connected.
10. If the shuttle frame assembly is a new or refurbished unit, adjust the
platen gap (page 162); otherwise, skip to step 11.
11. Install the shuttle cover assembly (page 203).
12. Models -014 and -015 only: adjust the coil temperature if the original
shuttle frame assembly was replaced (page 181).
13. Models -004, -04P, -005, and -05P only: set shuttle speed if the original
shuttle frame assembly was replaced (page 182).
14. Adjust the hammer phasing (page 173).
15. Return the printer to normal operation (page 153).
244
Chapter 7 Section I: Replacement Procedures
Spring, Extension
ATTENTION
Do not let the hammer bank rotate toward the platen during spring
replacement.
Removal
1. Prepare the printer for maintenance (page 152).
2. Open the printer cover.
3. Remove the shuttle cover assembly (page 203).
4. Unhook the extension spring from the spring lugs on the hammer bank
and shuttle frame. (See Figure 49, page 272.)
Installation
1. Put a dab of IBM #20 bearing lubricant on both spring lugs.
ATTENTION
Make sure the extension spring does not touch the MPU cable after
installation.
2. Hook the extension spring over the spring lugs. (See Figure 49, page
272.)
3. Install the shuttle cover assembly (page 203).
4. Return the printer to normal operation (page 153).
Switch Assembly, Cover Open
245
Switch Assembly, Cover Open
Removal
1. Prepare the printer for maintenance (page 152).
2. Remove the shuttle cover assembly (page 203).
3. Carefully lift and pry the cover open switch assembly out of its well in the
base casting to the right of the shuttle motor. (See Figure 47, page 264,
item 18.)
4. Trace the cover open switch cable back to the controller board, releasing
the cable from the restraints under the base casting. (See cable routing
diagrams on page 300 and page 302.)
5. Disconnect connector shell P107 (P7) from the controller board.
6. Trace the ribbon motor wires to the connector shell, and remove the cable
connector from the connector shell (page 195).
Installation
1. Remove the protective covering from the adhesive backing on the cover
open switch assembly.
2. Feed the switch cable down into the cover open switch well to the right of
the shuttle motor. Position the cover open switch assembly in the base
casting and press it into place. (See Figure 47, page 264, item 18.)
3. Route the cover open switch cable back to the controller board, installing
the cable in the restraints under the base casting. (See cable routing
diagrams on page 300 and page 302.)
4. Connect the cover open cable to the connector shell (page 195), then
connect the connector shell P107 (P7) to the controller board.
5. Install the shuttle cover assembly (page 203).
6. Return the printer to normal operation (page 153).
246
Chapter 7 Section I: Replacement Procedures
Switch Assembly, Paper Detector
Removal
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Cabinet Model: Loosen four screws and remove the barrier shield.
(See page 258, Figure 44, items 3 and 4.)
Pedestal Model: Remove the paper guide, barrier shield, and four screws.
(See page 260, Figure 45, items 3, 4, and 5.)
4. Remove the two screws securing the paper detector switch assembly.
(See Figure 52, page 278.)
5. Trace the paper detector switch cables back to the controller board,
releasing the cables from the restraints under the base casting. (See
cable routing diagrams on page 300 and page 302.)
6. Disconnect connector shell P106 from the controller board.
7. Remove switch cable connectors PMD and POD from connector P106
(page 195).
8. Remove the paper detector switch assembly.
Installation
1. Holding the slotted wheel against the PMD sensor, position the paper
detector switch assembly and install the screws securing it to the printer
base. (See Figure 52, page 278.)
2. Check the PMD sensor arm range: make sure it travels freely and
completely back into the sensing cavity.
3. Route switch cables PMD and POD back to the controller board, installing
the cables in the restraints under the base casting. (See cable routing
diagrams on page 300 and page 302.)
4. Connect switch cables PMD and POD to the connector P106 (page 195),
then connect P106 to controller board connector J106.
5. Cabinet Model: Install the barrier shield and tighten the four screws.
(See page 258, Figure 44, items 3 and 4.)
Pedestal Model: Install the paper guide, barrier shield, and four screws.
(See page 260, Figure 45, items 3, 4, and 5.)
6. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
7. Check and adjust the End of Forms Distance (page 169).
8. Return the printer to normal operation (page 153).
Switch Assembly, Platen Interlock
247
Switch Assembly, Platen Interlock
Removal
1. Prepare the printer for maintenance (page 152).
2. Cabinet Model: Remove the paper guide assembly (page 229).
Pedestal Model: Remove the top cover assembly (page 204).
3. Fully close the forms thickness lever (position A).
4. Trace the platen interlock switch cable back to the controller board.
Remove tie wraps as necessary to free the cable. (See cable routing
diagrams on page 300 and page 302.)
5. Disconnect connector shell P107 (P7) from the controller board.
6. Remove the platen interlock cable connector from the connector shell
(page 195).
7. Remove two screws securing the platen interlock switch assembly. (See
Figure 51, page 276.)
8. Remove the platen interlock switch assembly from the switch bracket.
9. Remove the switch cable from the cutout in the right side plate.
Installation
1. Fully close the forms thickness lever (position A).
2. Position the platen interlock switch assembly on the switch bracket and
install the two screws securing it to the bracket. (See Figure 51, page
276.)
3. Route the switch cable through the cutout in the right side plate and to the
controller board. (See cable routing diagrams on page 300 and page
302.)
4. Connect the platen interlock switch cable to the connector shell P107 (P7)
(see page 195), then connect the connector shell to the controller board.
5. Cabinet Model: Install the paper guide assembly (page 229).
Pedestal Model: Install the top cover assembly (page 204).
6. Return the printer to normal operation (page 153).
248
Chapter 7 Section I: Replacement Procedures
Tractor (L/R)
Removal
1. Prepare the printer for maintenance (page 152).
2. Remove the splined shaft (page 239).
3. Remove the support shaft (page 241).
4. Remove the tractors.
Installation
1. Using the replacement tractors, install the support shaft (page 241).
2. Install the splined shaft (page 239).
3. Return the printer to normal operation (page 153).
Illustrations Of Printer Components
249
Section II: Illustrated Parts Lists
Only field-replaceable spares are given part numbers in the illustrated parts
lists. Part numbers are not listed for common fasteners and attachment
hardware. Items marked Ref in the illustrations refer to parts that are not
spared or are part of another assembly.
Illustrations Of Printer Components
Figure 40. Top Cover, Doors, and Casters, Cabinet Model ............ page 250
Figure 41. Paper Stacker and Chains ............................................. page 252
Figure 42. Control Panel and Cabinet Details................................. page 254
Figure 43. Pedestal Details ............................................................. page 256
Figure 44. Inside Covers, Cabinet Model ........................................ page 258
Figure 45. Inside Covers and Card Cage, Pedestal Model ............. page 260
Figure 46. Card Cage Detail, Pedestal Model................................. page 262
Figure 47. Print Mechanism and Circuit Boards: Early Models....... page 264
Figure 48. Print Mechanism and Circuit Boards: Later Models....... page 268
Figure 49. Magnetic Pickup Unit (MPU) and Extension Spring....... page 272
Figure 50. Tractor Shafts ................................................................ page 274
Figure 51. Platen............................................................................. page 276
Figure 52. Motors, Card Cage Fan, and Paper Detector Switch..... page 278
Figure 53. Circuit Breaker ............................................................... page 280
Figure 54. Expansion Coax/Twinax Board...................................... page 282
Figure 55. Ethernet Interface Assemblies ....................................... page 284
250
Chapter 7 Section II: Illustrated Parts Lists
Figure 40. Top Cover, Doors, and Casters, Cabinet Model
1
2
3
4
5
6
7
13
8
12
9
14
15
Illustrations Of Printer Components
251
Item
No.
Part No.
(Order No.)
Description Notes
1 24H8961 Top Cover Kit Includes mounting hardware
2 57G1492 Window, Top Cover Not visible in Figure 40
3 14H5567 Wireform Paper Guide Assembly Includes mounting hardware
4 24H8960 Rear Door Kit Includes item 14
5 24H8959 Front Door Kit Includes item 14
6 57G1485 Caster, with Brake Two at front
7 57G1486 Caster, without Brake Two at rear
8 14H5603 Logo, 6400
9 30H4008 Wire Rope, Front and Rear One on each door (Rear not
shown in Figure 40)
10 30H3986 Shipping Container Kit Cabinet models only
(Not shown in Figure 40)
11 14H5572 Hardware Kit Not shown in Figure 40
12 63H7510 Door Seal Kit
13 63H7398 Top Cover Seal Kit
14 93F7037 Hinge Plate, Top Included in items 4 and 5
15 57G1484 Hinge Plate, Bottom
252
Chapter 7 Section II: Illustrated Parts Lists
Figure 41. Paper Stacker and Chains
6
5
7
1
8
3
2
4
Illustrations Of Printer Components
253
Item
No.
Part No.
(Order No.)
Description Notes
1 57G7176 Stacker
2 30H3981 Runner, Stacker
3 04H4779 Riser, Stacker Runner
4 Ref Screw (4)
5 14H5296 Spares Kit, Grommet
6 14H5272 Chain Assembly Kit Kit contains eight chains
7 57G7260 Power Cord, U.S.
9 Ref Grommet, Power Cord (2) Included in item 5
254
Chapter 7 Section II: Illustrated Parts Lists
Figure 42. Operator Panel and Cabinet Details
$
$
1
3
6
5
7
8
6
6
9
2
Illustrations Of Printer Components
255
Item
No.
Part No.
(Order No.)
Description Notes
1 14H5299 Operator Panel, Cabinet Includes mounting hardware
2 57G1598
57G1599
57G1600
57G1601
57G1602
57G1603
57G1604
Operator Panel Overlay
Operator Panel Overlay
Operator Panel Overlay
Operator Panel Overlay
Operator Panel Overlay
Operator Panel Overlay
Operator Panel Overlay
English
Spanish
French
Italian
German
Dutch
Brazilian Portuguese
3 Ref Screw, Hex w/Lock Washer (4) 6-32x.375
4 14H5300 Cable Assy, Operator Panel
5 57G1481 Dashpot Kit Includes ball studs, spring
clips, and mounting hardware
6 Ref Screw w/Lock Washer (3) 6-32x.375
7 Ref Screw w/Lock Washer (2) 6-32x.175
8 57G1440 Fan Assembly
9 Ref Duct, Air Exhaust
256
Chapter 7 Section II: Illustrated Parts Lists
Figure 43. Pedestal Details
1
2
7
3
4
5
13
10
11
15
8
9
14
12
6
NOTE:
Item 16: Lid Accessory Kit not shown
Item 17: Pedestal Shipping Container not shown
Illustrations Of Printer Components
257
Item
No.
Part No.
(Order No.)
Description Notes
1 63H5124 Operator Panel, Pedestal Models 04P, 05P, 08P, 09P
2 57G1598
57G1599
57G1600
57G1601
57G1602
57G1603
57G1604
Operator Panel Overlay
Operator Panel Overlay
Operator Panel Overlay
Operator Panel Overlay
Operator Panel Overlay
Operator Panel Overlay
Operator Panel Overlay
English
Spanish
French
Italian
German
Dutch
Brazilian Portuguese
3 Ref Screw (5) 6-32x.50
4 63H5125 Bracket, Operator Panel Models 04P, 05P, 08P, 09P
5 63H5121 Hinge Lid Kit Models 04P, 05P, 08P, 09P
6 14H5300 Cable Assy, Operator Panel
7 63H5119 Lid, Pedestal Model Models 04P, 05P, 08P, 09P
8 Ref Screw (2)
9 63H5120 Top Cover Models 04P, 05P, 08P, 09P
10 Ref Screw (4) 10-32x.625
11 63H5118 Paper Basket Models 04P, 05P, 08P, 09P
12 63H7509 Caster, Pedestal Models 04P, 05P, 08P, 09P
13 63H5117 Pedestal Kit Models 04P, 05P, 08P, 09P
14 Ref Screw, Captive (2)
15 24H8533 Input Tray Optional item on models 04P,
05P, 08P, 09P
16 63H5122 Lid Accessory Kit Replacement acoustic seals
(Not shown in Figure 13)
17 64H5123 Shipping Container, Pedestal Models 04P, 05P, 08P, 09P
(Not shown in Figure 13)
258
Chapter 7 Section II: Illustrated Parts Lists
Figure 44. Inside Covers, Cabinet Model
1
2
11
3
4
9
10
3
8
7
6
5
Illustrations Of Printer Components
259
Item
No.
Part No.
(Order No.)
Description Notes
1 14H5235 Shroud Assembly, Air Shuttle Cover Assembly
2 Ref Screw, Captive (2) 10-24x.62 with O-ring,
.125x.250x.06
3 Ref Screw, Thread Forming (4) 6-32x.25
4 Ref Barrier Shield
5 14H5271 Paper Guide Assembly Models 004, 005, 008, 009,
012, 014
6 Ref Screw, w/Lock Washer (3) 6-32x.25 and #6 Flat Washer
7 14H5174 Platen/Paper Feed Cover Kit Paper feed belt cover shown
in Figure 44. Platen open belt
cover: item 24, page 276.
8 57G1468 Belt, Timing, 050P, 100 Teeth Paper Feed Belt
9 08H7954 Anti-Static Brush Kit
10 Ref Power Supply Shield Taped to card cage along
upper edge
11 14H5179 Paper Scale
260
Chapter 7 Section II: Illustrated Parts Lists
Figure 45. Inside Covers and Card Cage, Pedestal Model
See Figure 46,
page 262.
1
2
10
$
5
3
4
3
6
7
8
9
Illustrations Of Printer Components
261
Item
No.
Part No.
(Order No.)
Description Notes
1 14H5235 Shroud Assembly, Air Shuttle Cover Assembly
2 Ref Screw, Captive (2) 10-24x.62 with O-ring,
.125x.250x.06
3 Ref Screw, Thread Forming (4) 6-32x.25
4 Ref Barrier Shield
5 63H5116 Paper Path Assembly Models 04P, 05P, 08P, 09P
6 08H7954 Anti-Static Brush Kit
7 Ref Power Supply Shield Taped to card cage along
upper edge
8 57G1468 Belt, Timing, 050P, 100 Teeth Paper Feed Belt
9 14H5174 Platen/Paper Feed Cover Kit Paper feed belt cover shown
in Figure 45. Platen open belt
cover: item 24, page 276.
10 14H5179 Paper Scale
262
Chapter 7 Section II: Illustrated Parts Lists
Figure 46. Card Cage Detail, Pedestal Model
From Figure 45, page 260.
Rotated 180 degrees.
5
$
To IEC 320 AC
Power Input
(Connector
J301, White
Wire)
To Connector P1
(Black Wire)
To IEC 320 AC Power
Input (Connector J301,
Black Wire)
To Connector P1
(White Wire)
1
2
3
4
6
Illustrations Of Printer Components
263
Item
No.
Part No.
(Order No.)
Description Notes
1 Ref Nut, 6-32 (1) Upper right fan corner only
2 57G1440 Card Cage Fan Assembly Air flow is into card cage
3 Ref Fan Guard
4 Ref Screw, w/Lock Washer (4) 6-32x.1.75
5 Ref Card Cage, Pedestal
6 14H5571 Circuit Breaker
264
Chapter 7 Section II: Illustrated Parts Lists
Figure 47. Print Mechanism and Circuit Boards: Early Models
1
Two places:
Exploded to show
assembly. Do not
remove holddown
clamps and
screws.
14
To J02
(Shuttle
Motor) To J03
(MPU)
2
7
8
9
10
4
6
To Terminator
Board on Shuttle
Frame
11
16
17
18
12
13
15
15
15
5
3
Illustrations Of Printer Components
265
Item
No.
Part No.
(Order No.)
Description Notes
1 63H7518
63H7519
63H7520
Hammer Bank/Rbn Mask Cover
Hammer Bank/Rbn Mask Cover
Hammer Bank/Rbn Mask Cover
Models 004, 04P, 005, 05P
Models 008, 08P, 009, 09P
Models 012, 014
2 14H5274
24H8648
14H5516
24H9625
14H5517
90H3269
14H5275
14H5512
14H5513
Shuttle Frame Assembly
Shuttle Frame Assembly
Shuttle Frame Assembly
Shuttle Frame Assembly
Shuttle Frame Assembly
Shuttle Frame Assembly
Hammer Spring Assembly
Hammer Spring Assembly
Hammer Spring Assembly
Models 004, 04P
Models 005, 05P
Models 008, 08P
Models 009, 09P
Model 012
Model 014
Models 004, 04P, 005, 05P
Models 008, 08P, 009, 09P
Models 012, 014
3 14H5644
90H3268
Power Supply PCBA
Power Supply PCBA
Models 004, 04P, 005, 05P, 008,
08P, 012
Models 009, 09P, 014
4 Ref P101 Cable Connector
5 Ref Cable Assy, AC-In, Power Supply Part of Field Kit, AC Assy
14H5289
6 14H5643
24H8647
90H3271
Controller Board, CMX, V5.0
Controller Board, CMX, V5.5, 25
MHz
Controller Board, CMX, V5.5, 40
MHz
All models 004 and 04P. Models
008 and 012 with Ser. Nos.
01AXXXX, 01BXXXX and
01CXXXX
All models 005, 05P, and 08P.
Models 008 and 012 with Ser.
Nos.01DXXXX, 01EXXX, and
higher. All models 009, 09P.
Model 014, 050, P50, 010, P10,
015
7 Ref Motor Sensor, Left, Cable Assy Housing Connector Kit 14H5288
8 Ref Hammer Bank Logic Cable Assy
9 Ref Shuttle Motor Cable Assy
10 Ref Hammer Bank Power Cable Assy
11 Ref Motor Sensor, Right, Cable Assy Housing Connector Kit 14H5288
12 14H5287
14H5522
Centronics I/O Cable Assy
Centronics/Dataproducts Adapter Optional cable assembly
13 Ref Control Panel Cable Assy
14 14H5211 Clamp, Shaft, Receiving
15 Ref Screw, Captive, Power Supply (3)
266
Chapter 7 Section II: Illustrated Parts Lists
16 Ref SIMM, Flash Memory See also page 217
17 Ref SIMM, DRAM See also page 217
18 14H5282 Switch Assembly, Cover Open
Item
No.
Part No.
(Order No.)
Description Notes
Illustrations Of Printer Components
267
(Illustrated parts lists continue on next page.)
268
Chapter 7 Section II: Illustrated Parts Lists
Figure 48. Print Mechanism and Circuit Boards: Later Models
To J02
(Shuttle
Motor) To J03
(MPU)
To Terminator
Board on Shuttle
Frame
Two places:
Exploded to show
assembly. Do not
remove holddown
clamps and
screws.
17
5
10
11
13
7
9
14
19
20
21
15
16
18
18
18
8
6
12
1
4
2
3
4
22
22
Illustrations Of Printer Components
269
Item
No.
Part No.
(Order No.)
Description Notes
1 24H8872
24H8886
24H8924
63H7520
Hammer Bank Cover Assy, 500
Hammer Bank Cover Assy, 1000
Hammer Bank Cover Assy, 1500
Hammer Bank Cover Assy, Hanzi
Models 050, P50
Models 010, P10
Model 015
Models C05, C5P
2 24H8828
24H8844
24H8858
Ribbon Mask, 500
Ribbon Mask, 1000
Ribbon Mask, 1500
Models 050, P50
Models 010, P10
Model 015
3 Ref Ribbon Mask Clamp Plate (3)
4 Ref Screw, Torx T-10 (18) 12 for hammer bank cover
6 for ribbon mask
5 24H8925
24H8927
24H8929
24L5207
24H8931
24H8932
24H8933
24L5209
Shuttle Frame Assembly, 500
Shuttle Frame Assembly, 1000
Shuttle Frame Assembly, 1500
Shuttle Frame Assembly, Hanzi
Hammer Spring Field Kit, 500
Hammer Spring Field Kit, 1000
Hammer Spring Field Kit, 1500
Hammer Spring Field Kit, Hanzi
Models 050, P50
Models 010, P10
Model 015
Models C05, C5P
Models 050, P50
Models 010, P10
Model 015
Models C05, C5P
6 90H3268 Power Supply PCBA
7 Ref P101 Cable Connector
8 Ref Cable Assy, AC-In, Power Supply Part of Field Kit AC Assy
14H5289
9 90H3271 Controller Board, CMX, V5.5, 40 MHz Models 050, P50, 010, P10,
014, 015, C05, C5P
10 Ref Motor Sensor, Left, Cable Assembly Housing Connector Kit
14H5288
11 Ref Hammer Bank Logic Cable Assembly
12 Ref Shuttle Motor Cable Assembly
13 Ref Hammer Bank Power Cable Assy
14 Ref Motor Sensor, Right, Cable Assembly Housing Connector Kit
14H5288
15 14H5287
14H5522
Centronics I/O Cable Assembly
Centronics/Dataproducts Adapter Optional cable assembly
16 Ref Control Panel Cable Assembly
17 14H5211 Clamp, Shaft, Receiving
18 Ref Screw, Captive, Power Supply (3)
270
Chapter 7 Section II: Illustrated Parts Lists
19 Ref SIMM, Flash Memory See also page 217
20 Ref SIMM, DRAM See also page 217
21 14H5282 Switch Assembly, Cover Open
22 02N8261 Connector Clip
Item
No.
Part No.
(Order No.)
Description Notes
Illustrations Of Printer Components
271
(Illustrated parts lists continue on next page.)
272
Chapter 7 Section II: Illustrated Parts Lists
Figure 49. Magnetic Pickup Unit (MPU) and Extension Spring
0.010 + .001 inch (0.254 + .025mm)
<21> Make sure the extension
spring does not touch the MPU
cable after installation.
Spring Lug (Do not
remove grease)
Spring Lug (Do not
remove grease)
4
1
2
3
Illustrations Of Printer Components
273
Item
No.
Part No.
(Order No.)
Description Notes
1 57G1476 Magnetic Pickup Assy (MPU)
2 Ref Screw, Socket Cap, 6-32x.38
3 30H3985 Extension Spring
4 14H5329 Cable Assembly, MPU
274
Chapter 7 Section II: Illustrated Parts Lists
Figure 50. Tractor Shafts
NOTE
Item 18: Tractor Shaft Hardware Kit not shown
Item 19: Tractor Shaft Kit not shown
2
3
17
4
5
7
9
10
11
20
21
12
14
13
16
15
16
6
8
1
22
23
Illustrations Of Printer Components
275
Item
No.
Part No.
(Order No.)
Description Notes
1 Ref Screw, Socket Cap, 4-40x.25 Part of item 19
2 Ref Washer, Flat #4 Part of item 19
3 Ref Knob, Tractor Adjust Part of item 19
4 Ref Bushing, Tractor Adjust Part of item 19
5 Ref Washer, Curved Spring (2) Part of item 19
6 Ref Ring, Grip Part of item 18
7 Ref Bearing, Nylon .626 Part of item 18
8 Ref Link Spring Part of item 18
9 Ref Spring, Extension 1.00L Part of item 18
10 Ref Screw, Hex w/Lock Washer, 4-20x.50 Part of item 11
11 57G1521 Ground Clip, Splined Shaft
12 57G1460 Splined Shaft Assembly
13 Ref Screw, Thread Forming, 6-32x.25 Part of item 18
14 Ref Clamp, Bearing Part of item 18
15 Ref Tractor Support Shaft Part of item 19
16 57G1466 Tractor Set Includes L and R tractors
17 Ref E-Ring Part of item 19
18 14H5217 Tractor Shaft Hardware Kit
19 14H5214 Tractor Shaft Kit
20 Ref Bushing Part of item 18
21 24H8593 Paper Support (2)
22 Ref Link, Splined Shaft Skew Adjustment
23 01P4611 Tractor Assembly, Power Stacker Installed at factory on models
with power stacker.
276
Chapter 7 Section II: Illustrated Parts Lists
Figure 51. Platen
NOTE:
Black tape faces
paper motion
detector.
NOTE:
Item 25: Platen
Hardware Kit
1
2
4
3
5
6
7
8
8
2
9
10
13
12
11
14
15
16
19
24
23
18
21
17
26
16
20
22
18 17
Illustrations Of Printer Components
277
Item
No.
Part No.
(Order No.)
Description Notes
1 Ref Setscrew Part of item 25
2 Ref Bracket, Platen (2) Part of item 25
3 57G1469 Ironer Assembly Reverser Paper Feed
4 Ref Screw, Thread Forming (3) 6-32x.25
5 57G1571 Bracket, Ironer
6 Ref Plate, Ironer
7 08H7936 Platen Assembly
8 Ref Washer, Flat (2) Part of item 25
9 Ref Screw (2) Part of item 11
10 Ref Washer, Flat #4 (2) Part of item 11
11 14H5280 Platen Switch Kit Platen Interlock Switch
12 Ref Screw, Socket Cap, 6-32x.75 Part of item 15
13 Ref Washer Part of item 15
14 Ref Nut Part of item 15
15 63H7478 Platen Lever Kit
16 Ref Spring, Extension 1.12L Part of item 25
17 Ref Link, Spring Part of item 25
18 Ref Bearing, Nylon .376 Part of item 25
19 Ref Bracket, Switch Mount Part of item 11
20 Ref Wear Saddle, Platen (2) Part of item 25
21 57G1514 Platen Pulley, Driven
22 Ref Screw, Socket Cap, 6-32x.44 Part of item 21
23 57G1467 Belt, Timing, 312W, 87 Teeth Platen Open Belt
24 14H5174 Platen/Paper Feed Cover Kit Platen open belt cover shown
in Figure 51. Paper feed belt
cover: page 258, item 7.
25 14H5169 Platen Hardware Kit
26 Ref Platen Washer Part of item 25
278
Chapter 7 Section II: Illustrated Parts Lists
Figure 52. Motors, Card Cage Fan, and Paper Detector Switch
Install screws here
Hammer Bank Fan
Route cable under
base casting
Top View
$
1
2
16
20
18
19
17
15
6
12
4
5
2
7
9
10
11
13
14
21
22
11
$
See detail above
22
4
3
8
Illustrations Of Printer Components
279
Item
No.
Part No.
(Order No.)
Description Notes
1 57G1440 Fan Assembly Air flow is into card cage
2 Ref Screw, w/Lock Washer (3) Two 6-32x1.75 on botton
One 6-32x0.50 on top left
3 14H5281
14H5570
Paper Detector Switch Assy
Paper Detector Switch Assy
Standard
Black Back forms
4 Ref Screw, Thread Forming, 6-32x.375
5 14H5520 Paper Feed Motor Assy Includes items 7 through 9
6 08H7934 Motor Pulley, Platen Open Part of Platen Open Motor
Assy 57G1509 and includes
collar setscrew 6-32x.25
7 Ref Collar Part of item 9
8 Ref Screw, Socket Head, 6-32x.51
9 57G1421 Motor Pulley, Paper Feed
10 Ref Screw, Hex w/Lock Washer (2) 10-32x.50
11 24H8894 Ribbon Guide Kit Includes left and right ribbon
guides
12 14H5154 Platen Open Motor Assembly Includes item 6
13 Ref Washer, Flat #4 (2)
14 Ref Screw, Hex w/Lock Washer (2) 4-40x.38
15 Ref Screw, Hex w/Lock Washer (2) 10-32x.50
16 Ref Shield, Card Cage Fan
17 14H5521 Motor Assembly, Ribbon
18 Ref Screw, Hex w/Lock Washer (2) 6-32x.50
19 Ref Washer, Flat #6 (2)
20 57G1479 Ribbon Hub Kit
21 Ref Screw, w/Lock Washer (2) 6-32x1.25
22 14H5159 Hammer Bank Fan Assembly Air flow is up
23 Ref Boot Cabinet models only
280
Chapter 7 Section II: Illustrated Parts Lists
Figure 53. Circuit Breaker
To IEC 320 AC Power
Input (Connector J301,
White Wire)
To Connector P1
(Black Wire)
To IEC 320 AC Power
Input (Connector J301,
Black Wire)
To Connector P1
(White Wire)
$
%
$
%
See inside detail below.
Card cage fan and
power supply board
removed for clarity.
4
5
3
2
White Wire
Black Wire
White Wire
Black Wire
1
Illustrations Of Printer Components
281
Item
No.
Part No.
(Order No.)
Description Notes
1 14H5571 Circuit Breaker
2 Ref IEC 320 AC Power Connector Connector J301
3 Ref Chassis Ground Stud
4 Ref Connector P1 To power supply board
connector J1 AC
5 Ref Cable Assy, AC-In, Power Supply Part of Field Kit, AC Assy
14H5289
282
Chapter 7 Section II: Illustrated Parts Lists
Figure 54. IBM Coax/Twinax Expansion Board
1
2
3
4
5
6
8
7
Illustrations Of Printer Components
283
Item
No.
Part No.
(Order No.)
Description Notes
1 Ref Screw (2)
2 Ref Card Cage
3 24H9011 IBM Coax/Twinax Expansion
4 Ref Screw, Captive
5 Ref Standoff, Hex, 3/16 inch M/F, .813 Lg.
6 24H8535 Adapter, Expansion Connector 60-pin
7 Ref CMX Controller Board
8 Ref Controller Board Connector J111
284
Chapter 7 Section II: Illustrated Parts Lists
Figure 55. Ethernet Interface Assemblies
1
2
3
4
5
6
7
9
10
8
Illustrations Of Printer Components
285
Item
No.
Part No.
(Order No.)
Description Notes
1 Ref Screw, Connector Cover (2)
2 Ref Cover Plate, Centronics
3 Ref Ferrite Clamp See also Appendix I
4 Ref CMX Controller Board
5 14H5287 Centronics I/O Cable Assembly
6 24H8995 Ethernet LAN PCBA, 10Base-T
7 24H8994 Ethernet LAN PCBA, 10Base2
8 02N8315 Ethernet LAN PCBA, 10/100Base-T
9 Ref Rear of Card Cage
10 Ref Screw (2)
286
Chapter 7 Section II: Illustrated Parts Lists
287
A Wire Data
Circuit Board And Cable Pinouts
NOTE: Acronyms and signal mnemonics are defined in Appendix C.
Interconnection Diagram................................................................. page 289
Power Distribution Diagram ............................................................ page 290
Main Wire Harness Test Tables...................................................... page 291
Circuit Board Pinouts
Controller, CMX........................................................................ page 292
Power Supply............................................................................ page 296
IBM Coax/Twinax Expansion Board ......................................... page 297
SureStak
1
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299
Cable Routing, Cabinet Model
3
0
0
A
p
p
e
n
d
i
x
A
C
i
r
c
u
i
t
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B
a
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e
,
C
a
b
i
n
e
t
M
o
d
e
l
To J107 on CMX board
To J106 on CMX board
Front of Printer
Left Side of Printer
Right Side of Printer
NOTE: This view shows the underside of the
mechanism base.
L RBN M
CABLE ASSY
301
Cable Routing, Pedestal Model
3
0
2
A
p
p
e
n
d
i
x
A
C
i
r
c
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e
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t
a
l
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o
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e
l
on Controller
on Controller
Left Side
Right Side
Front of Printer
of Printer
of Printer
(See page 166 for
connector detail.)
(See page 166 for
connector detail.)
(Not connected
on pedestal models)
To J107 on CMX board
To J106 on CMX board
NOTE: This view shows the underside of the
mechanism base.
P306
TO CARD
CAGE FAN
PLAT M
P106/CCF
P106/LRP
303
Cable Assembly, Centronics I/O
PIN 1
PIN 1
NOTE:
If you replace the I/O cable
assembly, you must install
the ferrite clamp.
See Appendix E.
NOTE: If you replace this cable,
you must also install a ferrite clamp.
See Appendix I.
14H5287
304
Appendix A Circuit Board And Cable Pinouts
Cable Assembly, Centronics/Dataproducts Adapter
14H5522
305
Cable Assembly, +5V Remote Power
14H5589
306
Appendix A Circuit Board And Cable Pinouts
Cable Assembly, Twinax Auto-Termination
White
Gray
Shield
14
7
5
Jack
Jack
1 2
3 4
Resistance Chart
Pin Pin Ohms
1
3
1, 2, 3, 4
5
14
7
2
4
Shield
Shield
1, 4
2, 3
110
110
55
0
0
0
38F8254
307
Cable Assembly, AC-In, Power Supply
To Power Supply J1
To Circuit Breaker
AC Kit: 14H5289
308
Appendix A Circuit Board And Cable Pinouts
Cable Assembly, AC Power Input
To Circuit Breaker
Input Power Connector
AC Kit: 14H5289
309
Cable Assembly, Card Cage Fan
PIN 1
PIN 1
14H5285
310
Appendix A Circuit Board And Cable Pinouts
Cable Assembly, Operator Panel
PIN 1
PIN 1
PIN 8
PIN 8
(Gray)
(Brown)
(Gray)
(Brown)
NOTE: If you replace the control panel cable,
you must install two ferrite shielding beads.
See Appendix I.
14H5300
311
Cable Assembly, Exhaust Fan
PIN 1
PIN 1
14H5286
312
Appendix A Circuit Board And Cable Pinouts
Cable Assembly, Hammer Bank Logic
14H5279
313
Cable Assembly, Hammer Bank Power
PIN 1
PIN 1
02N6214
314
Appendix A Circuit Board And Cable Pinouts
Cable Assembly, MPU
PIN 1
PIN 3
PIN 2
PIN 1
14H5329
315
Cable Assembly, Ribbon Guide Kit
24H8894
NOTE: Left ribbon guide shown.
Right is mirror image.
Pin Connection
P106 (LRP) / P107 (RRP) Wire Color
Pin 1 Black
Pin 2 Black
Left Guide = P106 / LRP
Right Guide = P107 / RRP
Pin 1
Pin 2
316
Appendix A Circuit Board And Cable Pinouts
Cable Assembly, Ribbon Motor, Extension
63H7464
317
Cable Assembly, Shuttle Motor Drive
14H5330
318
Appendix A Circuit Board And Cable Pinouts
Frame Cable, Power Stacker
123456789
1
0
1
1
1
2
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1
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2
1
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4
2
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2
6
2
7
2
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2
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=
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5
.
2
1
.
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O
h
m
/
P
h
a
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2
=
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R
O
N
T
P
A
D
D
L
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M
O
T
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R
R
e
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e
=
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5
.
2
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.
5
O
h
m
/
P
h
a
s
e
P
I
N
C
H
R
O
L
L
E
R
M
O
T
O
R
R
e
s
i
s
t
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n
c
e
=
1
5
.
2
1
.
5
O
h
m
/
P
h
a
s
e
(
R
e
f
e
r
e
n
c
e
o
n
l
y
:
n
o
t
s
p
a
r
e
d
.
)
319
Logic Cable, Power Stacker
24H8976
320
Appendix A Circuit Board And Cable Pinouts
Power Cable, Power Stacker
24H8975
321
Vertical Rail Cable, Power Stacker
(Reference only: not spared.)
322
Appendix A Circuit Board And Cable Pinouts
Fan Assembly, Hammer Bank
P
1
0
7
/
H
B
F
P 1 0 7 / H B F
1
4
H
5
1
5
9
323
Magnetic Pickup (MPU) Assembly
57G1476
324
Appendix A Circuit Board And Cable Pinouts
Switch Assembly, Paper Detector
S
t
a
n
d
a
r
d
:
1
4
H
5
2
8
1
B
l
a
c
k
B
a
c
k
F
o
r
m
s
K
i
t
:
1
4
H
5
5
7
0
325
Switch Assembly, Platen Interlock
P
1
0
7
/
P
L
O
14H5280
326
Appendix A Circuit Board And Cable Pinouts
Switch Assembly, Cover Open
14H5282
327
B Printer Specifications
Ribbon Specifications
The ribbon life figures listed below are based on IBM tests conducted in
accordance with ANSI Standard X3A.182. Actual ribbon life may vary,
depending on the users quality criteria, printer condition, machine settings,
paper quality, and bar code requirements. Label yield depends on label
format, bar code symbology, and other parameters. Label yield with high-
performance scanning equipment may exceed these yields. Use only the
ribbons listed below.
IBM General Purpose Ribbon: P/N 1040990
Used for general text printing such as data and word processing.
Average yield: 20 million DP characters
IBM General Purpose Ribbon: P/N 1040995
Average yield: 30 million DP characters
IBM High Contrast Ribbon: P/N 1040993
Used for general text printing as well as OCR, graphics and bar code
printing.
Average yield: 20 million DP characters, 2500 AIAG-B3 labels with visible
light source scanning equipment, or 1300 AIAG-B3 labels with infrared
light source scanning equipment.
IBM High Contrast Ribbon: P/N 1040998
Average yield: 30 million DP characters, 3600 AIAG-B3 labels with visible
light source scanning equipment, or 1800 AIAG-B3 labels with infrared
light source scanning equipment.
IBM Hanzi Ribbon: P/N 1402739
100 Yard, Hi Resolution ribbon for all Hanzi printing requirements
Ordering Ribbons In The U.S.
Ribbons can be purchased from Lexmark Authorized IBM Supplies Dealers or
directly from Lexmark by calling 1-800-438-2468.
Send fax orders to 1-800-522-3422
Send mail orders to Lexmark International, Inc., 1221 Alverser Drive,
Midlothian, VA 23113.
328
Chapter Paper Specifications
Ordering Ribbons Outside Of The U.S.
Order supplies by contacting your local Lexmark International distributor or by
writing to Lexmark International, Inc., P.O. Box 11427, Lexington, KY, 40575-
1427, USA
Paper Specifications
The paper specifications in this section are guidelines only. Always test paper
stock with applications to determine print quality.
Paper
Type: Edge-perforated, fan-fold, 3 to 17 inches (7.62 to 43.18 cm) wide*, 2 to
24 inches (5.08 to 60.96 cm) long**
Single-part: 15 pound (57 g/m
2
) to 100 pound (377 g/m
2
) stock.
Multi-part carbon: 1- to 6-part forms, maximum 12 pound (45 g/m
2
) ply of
upper plies
Multi-part carbonless. Verify readability of greater than 4-part.
Thickness: 0.025 inches (0.064 cm) maximum
Drive: Adjustable tractors, 6-pin engagement
Labels
On Backing: One-part continuous perforated fan-fold back form. Labels must
be placed at least 1/6 inch (0.42 cm) from the fan-fold perforation. Backing
adhesive must not be squeezed out during printing.
Sheet Size: 3 to 17 inches (7.62 to 43.18 cm) wide*, including the two
standard perforated tractor feed strips. A maximum sheet length of 16 inches
(40.64 cm) between top and bottom perforations.**
Thickness: Not to exceed 0.025 inch (0.064 cm), including backing sheet.
* On pedestal models, when using the rear paper exit, the maximum width is
16 inches (40.64 cm).
** On cabinet models, forms longer than 12 inches (30.48 cm) can be printed
by opening the front and rear printer doors.
329
Printer Dimensions
Environmental Characteristics
Temperature
Operating:
41 to 104 F (5 to 40 C) up to 5000 feet (1524 meters)
41 to 90 F (5 to 32 C) up to 8000 feet (2438 meters)
Storage:
-40 to 158 F (-40 to 70 C)
Relative Humidity
Operating:
15% to 80% (noncondensing)
Storage:
15% to 90% (noncondensing)
ENERGY STAR**
IBM 6400 Series Printers comply with the requirements of the ENERGY
STAR Computers Program of the U.S. Environmental Protection Agency.
Cabinet Model Pedestal Model
Height 42.5 inches (108 cm) 35.5 inches (90.2 cm)
Width 27 inches (68.6 cm) 24.6 inches (62.5 cm)
Depth 29 inches (73.7 cm)
32.5 inches (82.6 cm) with
power stacker
30 inches (76.2 cm)
Weight 225 lbs. (102.1 kg)
285 lbs. (129.3 kg) packaged
120 lbs. (54.4 kg)
160 lbs. (72.6 kg) packaged
330
Chapter Electrical Characteristics
Electrical Characteristics
Input Voltage
Power Consumption
6400-004
6400-04P
Line
Voltage
Design
Range
Line
Frequency
RMS Current
-04,
-04P
-05,
-05P
-50,
-P50
-08,
-08P
-09,
-09P
-010,
-P10
-012 -014 -015
-C05,
-C5P
88-
135V
RMS
47-63 Hz 6A @
100 V
6A @
100 V
6A @
100 V
6A @
100 V
6A @
100 V
6A @
100 V
6A @
100 V
8A @
100 V
8A @
100 V
6A @
100 V
178-
270V
RMS
47-63 Hz 3A @
200 V
3A @
200 V
3A @
200 V
3A @
200 V
3A @
200 V
3A @
200 V
3A @
200 V
5A @
200 V
5A @
200 V
3A @
200 V
120 VAC
60 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 212 232 80 20
BTU/Hour 723 791 273 71
VA 321 348 133 34
240 VAC
50 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 212 227 82 21
BTU/Hour 723 775 279 71
VA 390 426 164 39
331
6400-005
6400-05P
6400-050
6400-P50
120 VAC
60 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 223 244 84 21
BTU/Hour 761 833 287 75
VA 338 366 140 36
240 VAC
50 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 223 239 86 22
BTU/Hour 761 816 294 75
VA 410 449 173 41
120 VAC
60 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 223 244 84 21
BTU/Hour 761 833 287 75
VA 338 366 140 36
240 VAC
50 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 223 239 86 22
BTU/Hour 761 816 294 75
332
Chapter Electrical Characteristics
6400-008
6400-08P
6400-009
6400-09P
VA 410 449 173 41
120 VAC
60 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 330 370 84 25
BTU/Hour 1126 1263 287 85
VA 450 492 140 48
240 VAC
50 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 320 360 86 25
BTU/Hour 1092 1228 294 85
VA 528 600 173 55
120 VAC
60 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 287 327 80 25
BTU/Hour 980 1116 273 85
VA 425 475 132 48
240 VAC
50 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
333
6400-010
6400-P10
6400-012
240 VAC
50 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 281 314 86 25
BTU/Hour 959 1072 294 85
VA 497 569 173 55
120 VAC
60 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 332 360 86 25
BTU/Hour 1133 1229 294 85
VA 457 527 143 48
240 VAC
50 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 306 360 81 25
BTU/Hour 1044 1229 276 85
VA 554 662 170 55
120 VAC
60 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 410 480 81 25
BTU/Hour 1399 1638 276 85
VA 540 624 170 48
334
Chapter Electrical Characteristics
6400-014
6400-015
240 VAC
50 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 400 470 81 25
BTU/Hour 1365 1604 276 85
VA 660 780 170 55
120 VAC
60 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 410 430 84 25
BTU/Hour 1399 1468 287 85
VA 540 564 139 48
240 VAC
50 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 410 420 81 25
BTU/Hour 1399 1433 276 85
VA 540 768 170 55
120 VAC
60 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 426 513 84 27
BTU/Hour 1453 1751 287 92
VA 587 727 139 50
335
6400-C05
6400-C5P
240 VAC
50 Hz
Operating HS Mode Standby
All Hs Max Typical
Not Energy
Star
Energy Star
Watts 424 490 79 27
BTU/Hour 1447 1672 270 92
VA 722 857 163 58
120 VAC
60 Hz
Max Typical
Standby
Not Energy Star Energy Star
Watts 341 49 25
BTU/Hour 1163 167 85
VA 475 79 48
240 VAC
50 Hz
Max Typical
Standby
Not Energy Star Energy Star
Watts 310 59 25
BTU/Hour 1058 201 85
VA 624 130 55
336
Chapter Interfaces
Interfaces
Duty Cycle
The duty cycles for IBM 6400 printers are listed below. These figures are
averages, subject to the conditions specified following the list.
Standard: PC Parallel, RS-232 serial, RS-422 serial
Optional: Coax/Twinax, Ethernet 10Base-T, Ethernet 10Base2,
Ethernet 10/100Base-T
Logic Levels: TTL, EIA-232E, EIA-422B
Data Format ASCII
Compatibility PC Parallel, EIA-232E, EIA-422B
Transfer
Rates
Up to 200 Kilobytes on parallel interface.
Up to 19.2K baud on RS-232 serial interface.
Up to 115.2K baud on RS-422 serial interface
6400-004, 04P 130, 000 pages per month
6400-005, 05P 130, 000 pages per month
6400-050, P50 130, 000 pages per month
6400-008, 08P 205, 000 pages per month
6400-009, 09P 205, 000 pages per month
6400-010, P10 205, 000 pages per month
6400-012 320, 000 pages per month
6400-014 376, 000 pages per month
6400-015 376, 000 pages per month
6400-C05, C5P 130, 000 pages per month
Under the following conditions:
Uppercase text characters only (no graphics)
6 lines per inch
10 characters per inch
63% character density or 83 characters per line
63% line density or 42 lines per 11-inch page
Single part (18 lb) paper
Printer is installed in accordance with the Setup Guide
Printer is maintained in accordance with this maintenance manual
337
C Metric Conversion Tables
Length
Torque and Force
Multiply By To Obtain
foot 0.3048* meter
foot 30.48* centimeter
foot 304.8* millimeter
inch 0.0254* meter
inch 2.54* centimeter
inch 25.4* millimeter
meter 3.280840 foot
centimeter 0.03280840 foot
millimeter 0.003280840 foot
meter 39.37008 inch
centimeter 0.3937008 inch
millimeter 0.03937008 inch
* Figure is exact
Multiply By To Obtain
inch-pound 0.11298 Newton-meter
foot-pound 1.3558 Newton-meter
Newton-meter 8.8511 inch-pound
Newton-meter 0.7376 foot-pound
338
Appendix C
Mass and Density
Temperature
Power
pound 4.4482 Newton
inch 0.22481 pound
Multiply By To Obtain
pound* 0.4535924 kilogram
ounce* 28.34952 gram
kilogram 2.204622 pound
gram 0.03527397 ounce
* avoirdupois
From To Use Formula
temperature Celsius (tc) temperature Fahrenheit (tf) tf = 1.8tc + 32
temperature Fahrenheit
(tf)
temperature Celsius (tc) tc = (tf -32)/1.8
Multiply By To Obtain
Btu (International Table)
hour
0.2930711 Watt
Watt 3.412141 Btu (International Table)
hour
Watt 0.001359621 horsepower (metric)
horsepower (metric) 735.499 Watt
Multiply By To Obtain
339
D Torque Table
The table below establishes the torque requirements for routine installation of
threaded fasteners. These requirements apply to fasteners made of steel, at a
minimum engagement of 3.5 threads, including chamfer and countersink. For
the most accurate torquing, apply anti-seize compound to fastener threads
before you torque the fastener.
Fastener sizes are listed as Numbered Size - Threads Per Inch. (For
example, 2-56 represents No. 2 Screw, 56 Threads Per Inch.)
Carbon Steel Fasteners (ANSI B18.6.3 - 1972)
Fastener
Size
Into Alum. or
Brass
25,000 psi
ultimate
tensile
strength
Into Steel
60,000 psi
ultimate
tensile
strength
Into Weld/
Press Studs
or Nuts
Into
Medium
Carbon
Steel
Fasteners
100,000 psi
ultimate
tensile
strength
2-56 25 2 in oz 36 2 in oz 30 2 in oz *
4-40 62 4 in oz 75 5 in oz 70 5 in oz *
6-32 122 7 in oz 150 10 in oz 135 10 in oz *
8-32 11 in lb 18 1 in lb 18 1 in lb *
10-24 20 1 in lb 25 1.5 in lb 21 1 in lb *
10-32 15 1 in lb 29 2 in lb 29 1 in lb *
1/4 - 20 40 3 in lb 62 4 in lb 62 4 in lb 105 5 in lb
Fastener Sizes
Torque for Routine Tightening of Threaded
Fasteners
4-40 UNC & 4-48 UNF 4 1 in lb
6-32 UNC & 6-40 UNF 11 1 in lb
8-32 UNC & 8-36 UNF 19 1 in lb
10-24 UNC & 10-32 UNF 25 1 in lb
340
Appendix D
341
E Safety Inspection Guide
Safety Inspections
Safety devices to protect customers, operators, and service personnel from
injury are installed in all IBM 6400 printers. Use this inspection guide as an aid
in identifying possible unsafe conditions in a 6400 series printer.
Perform the inspection steps outlined in this guide before the normal
inspection for Maintenance Agreement Qualification, or any time you are
instructed to make a safety inspection.
If you find any unsafe conditions, determine the severity of the hazard and
whether or not you can continue the inspection without first correcting the
problem.
NOTE: The correction of any unsafe condition is the customers
responsibility.
Preparation
You must have completed the Electrical Safety Training Course for IBM
Customer Engineers (self-study course 77170 or existing level) to do the
Safety Inspection.
Have the following items available:
Electrical Safety for IBM Customer Engineers, Order No. S229-8124.
A Fluke** meter (P/N 8496278) or similar device for resistance and
voltage measurements.
An ECOS** Electrical Safety Tester (P/N 6339695) in the United States or
a similar safety tester in other countries.
For each safety check on the following pages, do the steps in the order
presented. Do not omit any steps.
342
Appendix E Prepare The Printer for Inspection
Prepare The Printer for Inspection
To prepare the printer for a safety inspection, read the safety notices below,
then do the following steps.
1. Have the operator take the printer off-line.
2. Power off the printer.
3. Unplug the printer power cord from the customers power outlet.
Inspect Mechanical Parts
Top Cover And Cabinet Doors
1. Inspect the top cover:
a. Open the top cover. On cabinet models, make sure the gas spring
assembly holds the cover up in the open position.
b. Make sure the window is not cracked or broken.
c. Make sure the seal around the top cover is not cracked or broken.
d. Make sure there are no exposed or sharp edges.
e. Make sure the wireform paper path is undamaged.
f. Make sure the electrostatic discharge (ESD) fingers are not loose or
damaged. Make sure they touch the contact strips on the frame when
the cover is closed.
g. Close the top cover. Make sure the operator panel is centered in the
opening of the cover.
2. On cabinet models, inspect the front and rear cabinet doors:
a. Make sure the seals and magnetic strips are not loose or damaged.
<3> Hazardous voltages are present in the printer with the
power cord connected to the power source. Switch off
printer power and unplug the printer power cord before
proceeding.
<4> Do not connect or disconnect any communication port,
teleport, attachment connector, or power cord during an
electrical storm.
<5> Power off the printer and disconnect the power cord before
connecting or disconnecting a communication port,
teleport, or attachment cable connector.
DANGER
343
b. Make sure the restraining cable is attached and unbroken.
c. Make sure there are no exposed or sharp edges.
d. Open the rear cabinet door and inspect the lower rear paper path:
e. Make sure the service panel permitting access to the I/O plate and
circuit breaker (on/off switch) is installed.
f. Make sure the paper stacker tray assembly or optional power stacker
is in place and undamaged.
Print Mechanism
1. Open the printer top cover.
2. Make sure the shuttle cover is correctly installed and undamaged. (See
page 203.)
3. Make sure the paper guide assembly is correctly installed and
undamaged. (See page 229.)
Inspect Electrical Parts
Safety Ground Path
1. Make sure the printer power cord is unplugged.
2. Remove the paper guide assembly (page 229).
3. Make sure the ground cable from the circuit breaker power leads is
undamaged and firmly attached to the ground lug on the wall of the card
cage, as shown in Figure 56.
NOTE: Ground paths for the entire printer are summarized in Figure 57.
Figure 56. Circuit Breaker Ground, Cabinet Models
Ground Lug
NOTE: The card cage fan
and power supply board are
removed here for clarity.
Ground Cable (To Power
Supply J1)
IEC 320 AC Power
Connector (J301)
Circuit
Breaker
344
Appendix E Inspect Electrical Parts
4. Set a Fluke meter (P/N 8496278) or similar device to the lowest
resistance scale. Measure the resistance between the power cable
ground pin and the printer frame: safety ground circuits should measure
0.1 Ohm or less.
5. Install the paper guide assembly (page 229).
Figure 57. Ground Path Diagram
OPERATOR PANEL
+5 V
AC
POWER
Parallel
I/O P
1
1
2
J
1
1
2
SHIELD
GND
J
3
1
0
P310
J301
CIRCUIT
BREAKER
IEC 320
AC POWER
P
1
J
1
A
C
AC to DC
Power Supply
Board Line 1
Line 2 / Neutral
CHASSIS
GND
J108 HBL
P108 HBL
J105 HBP
P105 HBP
J116 SMD
P116 SMD
J107 MSR
P107 MSR
Exhaust
Fan
Paper Feed
Motor
Platen Open
Switch
Right Ribbon
Guide
Right Ribbon
Motor
Platen
Motor
Paper Motion
Detector
Paper Out
Detector
Left Ribbon
Motor
J106 MSL
P106 MSL
Card Cage
Fan
Left Ribbon
Guide
Hammer Bank
Fan
Shuttle Motor
Hammer Bank Board
Terminator Board
Shuttle
P
1
1
0
J
1
1
0
J101 DC POWER
Point
of
Common
Ground
Assy
CMX
Controller Board
+5 V
Ret
Ret
+48V
+48V
+48V
+5 V
+24V
Ret
+48V
Ret
+8.5V
Ret
+48V
Ret
+48V
+48V
+5 V
+5 V
+5 V
+8.5/+48V
Ret
Cabinet
models
only
+5 V Remote
Power
EIA-232-E
Serial I/O
1
2
3
4
5
6
7
8
9
10
11
12
N TEMP HI *
N STBY
+5V
+5V
+5V RET / LOGIC GND
+5V RET / LOGIC GND
+5V RET / LOGIC GND
+5V RET / LOGIC GND
+8.5V
+8.5V
+48V
+48V
* V3.5 BOARD PIN 1 = N TEMP HI
V4 BOARD PIN 1 = N AC FAIL
P101
Ret
345
Customer Power Source Service Check
Use an ECOS Electrical Safety Tester (P/N 6339695) in the United States or
a similar safety tester in other countries.
NOTE: The ECOS tester will trip ground fault detector protected outlets. This
is a good test of the ground fault detector. Reset the outlet as needed.
Plug the ECOS meter into the customers outlet. Follow the instructions
supplied with the meter to test for the following:
Wiring errors
Low voltage
Neutral to ground short
Ground path impedance
Neutral impedance
NOTE: The customer is responsible for correcting problems with the power
source. Inform the IBM Installation Planning Representative (IPR) of
any problems with the customers power source.
Each branch circuit must be grounded for safety and correct operation of the
printer. This ground must be connected either to the electrical service ground
or to a suitable building ground. The printer power cable has a green or green/
yellow insulated grounding conductor. This is not a neutral line.
Power Cable
1. Make sure the power cable is not damaged.
2. Make sure the power plug is the correct type.
Power On / Off Verification
1. Make sure all covers are installed.
2. Plug the power cable into the customers power outlet.
3. Power on the printer and watch the LCD.
4. Verify that the power on diagnostic tests and initialization routines are
successful.
5. After successful initialization, the printer should cycle automatically to
either the READY or NOT READY mode, depending on which power on
state was selected when the printer was configured.
6. Power off the printer. Verify that the LCD goes completely blank and all
fans stop.
Print Interlock Service Check
1. Power on the printer.
2. Open the printer top cover.
3. Open the forms thickness lever. The LCD should display
057 CLOSE PLATEN and the audible alarm should sound if it is
enabled.
346
Appendix E Inspect Electrical Parts
4. Press Stop. The audible alarm should stop.
5. Close the forms thickness lever. The fault message should clear.
347
F Abbreviations And Signal
Mnemonics
NOTE: Mnemonics with the first letter N are negative true.
Abbreviation
or Mnemonic Definition
K 1,000 Ohms
Meg 1,000,000 Ohms
F microfarad (10
-6
farad)
s microsecond (10
-6
second)
sec microsecond (10
-6
second)
A0, A1, etc. Address 0, Address 1, etc.
AC Alternating Current
ACC Access
ACK Acknowledge
AMP Amplitude; Ampere
AMPL Amplitude
AN Anode
ASIC Application-Specific Integrated Circuit
ATTN Attention
B Buffered
BANK FAN Hammer Bank Fan
BCOM Buffered Communication
BCP Bi-phase Communications Processor
BHSC Buffered Hammer Shift Clock
BN Buffered, Low True
BNLD Buffered, Low True, Lower Driver
BPS Bits Per Second
BSY Busy
BTU British Thermal Unit
348
Appendix F
BUD Buffered Upper Driver
CA Cathode
CC Card Cage
CCF Card Cage Fan
CE Customer Engineer
CHNG Change
CIR Circuit
CLK Clock
CO Cover Open
COLL Collector
COMM Communication
CONTLR Controller
CMD Command
CMX Manufacturers designation of the controller board
CNC Connector, Connection
CPI Characters Per Inch
CR Carriage Return
CT Coaxial/Twinaxial
CTL Control
CTS Clear to Send
CUR Current
CVO Cover Open (Switch)
D0, D1, etc. Data Bit 0, Data Bit 1, etc.
DAT Data
DC Direct Current, Data Controller (a functional unit of
the CMX controller board)
DCD Data Carrier Detect
DIAG Diagnostic
DIFF Differential
DMA Direct Memory Access
DP Data Processing, DataProducts
DPMC Dot Plucker Memory Controller
DPU Data Processing Unit
DRAM Dynamic Random-Access Memory
DRV Drive or Driver
DRVR Driver
349
DSR Data Set Ready
DTR Data Terminal Ready
EC Engine Controller (a functional unit of the CMX board)
EEPROM Electrically Erasable/Programmable Read-Only Memory
EHF Exhaust Fan
EL Elevator (motor), Power Stacker
EMI ElectroMagnetic Interference
EMIT Emitter
EPROM Electrically Programmable Read-Only Memory
ERR Error
ESD Electrostatic Discharge
EX Exhaust, Extra
EXH Exhaust
EXF Exhaust Fan
EXP Expansion
EXPND Expand
FD Feed
FF Form Feed
FIFO First In, First Out
FLT Fault
FLTR Filter
FP Front Panel (Operator Panel)
FTIC Fire Timer Integrated Circuit
GND Ground
HB Hammer Bank
HBA Hammer Bank ASIC
HBF Hammer Bank Fan
HBL Hammer Bank, Left
HBP Hammer Bank Power
HBR Hammer Bank, Right
HD Hammer Driver
HDIC Hammer Driver Integrated Circuit
HDPH Hammer Driver Phase
350
Appendix F
HLP Hammer Bank Logic, Signals and Power
IC Integrated Circuit
ID Identification
IGP Intelligent Graphics Processor
IML Initial Microcode Load
INST Instruction
INT Interrupt
I/O Input/Output
IRQ Interrupt Request
(J) Jack connector
L Left
LCD Liquid Crystal Display
LED Light Emitting Diode
LF Line Feed
LO Low
LPI Lines Per Inch
LPM Lines Per Minute
LRIB Left Ribbon
LRP Left Ribbon Guide
M1 Rear Paddle Motor, Power Stacker
M2 Front Paddle Motor, Power Stacker
M Motor
MAIN Maintenance Jack, RS-232 (Optional)
MECA Mechanism Engine Control ASIC
MECH Mechanism
MF microfarad (10
-6
farad)
MH Mounting Hole
MOSFET Metal Oxide Semiconductor Field Effect Transistor
MOT Motor
MPU Magnetic Pickup (Unit)
ms millisecond (10
-3
second)
MSL Motor and Sensors, Left
MSR Motor and Sensors, Right
351
N Negative True
N/C Not Connected
NC Not Connected
NIC Network Interface Card (an optional Ethernet interface)
NLQ Near Letter Quality
No. Number
NOVRAM Non-volatile Random-Access Memory
ns nanosecond (10
-9
second)
NVRAM Non-volatile Random-Access Memory
NT Not
OLV On Line Verify
OP Operand
P5 + 5 V dc
(P) Pin connector
P(1), P(2), etc. Parallel data 1, data 2, etc.
PAL Programmable Array Logic
PAP Paper
PAPR Paper
PARM Parameter
PCBA Printed Circuit Board Assembly
PCB Printed Circuit Board
PE Printer Error, Paper Empty
PER Peripheral Device
PF picofarad (10
-12
farad)
PFC Paper Feed Controller
PFM Paper Feed Motor
PHA Phase A
PHB Phase B
PI Paper Instruction
PLAT Platen
PLM Platen Motor
PLO Platen Open (Switch)
PMD Paper Motion Detect (Switch)
PN Pin
352
Appendix F
P/N Part Number
PO Paper Out
POD Paper Out Detect (Switch)
PPR Paper
PROM Programmable Read-Only Memory
PS Power Supply
PS5 Power Supply + 5 Volt
PTR Pointer or Printer
PWM Pulse Width Modulation
PWR Power
R Right
RBN Ribbon
RD Read
RET Return
RIB Ribbon
RG Ribbon Guide
RGL Ribbon Guide, Left
RGR Ribbon Guide, Right
RM Ribbon Motor
RML Ribbon Motor, Left
RMR Ribbon Motor, Right
RQ Request
RRIB Right Ribbon
RRP Right Ribbon Guide
RSP Ribbon and Shuttle Processor
RST Reset
RTPU Real-Time Processing Unit
RTS Request to Send
RXD Receive Data
SCS SNA Character Stream
SEC Security (Key)
SEL Select
SEN Sense, Sensor
SF Structured Field
SG Signal Ground
353
SHH Shuttle Hall (Effect)
SHM Shuttle Motor
SHUT Shuttle
SHUTL Shuttle
SIMM Single Inline Memory Module
SLCT Select (On-line)
Slew Rapid vertical paper movement
SMD Shuttle Motor Drive
SNA Systems Network Architecture
SPU Shuttle Processor Unit
SRAM Static Random-Access Memory
STAT Status
STBY Standby
STK Power Stacker
SW Switch
SYNC Synchronize
TCB Task Control Block
TEMP Temperature
TOF Top of Form (first print line)
TP Test Point
TTL Transistor-Transistor Logic
TXD Transmit Data
UART Universal Asynchronous Receiver/Transmitter
UDPH Upper Drive Phase
UNDEF Undefined
USART Universal Synchronous/Asynchronous
Receiver/Transmitter
V Volts
V
CC
Voltage at Collector
V
DD
Voltage at Drain
V
SS
Voltage at Source
VX A special ASIC containing circuits that help the DC
controller operate. The letters VX do not stand for
anything; they simply designate this ASIC.
354
Appendix F
WR Write
w/ With
w/o Without
XMT Transmit
355
G Cords And Adapters
Part Number Description
1332167 Line Cord, IBM, Japan
1838573 Line Cord, IBM, 12 Feet, United States, 220 Volt
1838574 Line Cord, 220V 6 Feet Non-Lock, United States, Canada
6952299 Power Cord, 110V 12 Feet Non-Lock, United States, Canada, Brazil, Cayman
Islands, Costa Rica, Dominican Republic, El Salvador, Guatemala, Mexico,
Liberia, Panama, Saudi Arabia, Phillipines, Honduras, Peru, Columbia,
Nicaragua, Bermuda, Bahamas, Barbados, Bolivia, Guyana, Ecuador, Haiti,
Jamaica, Venezuela, Netherlands, Antilles, Trinidad, Suriname, Taiwan,
Tobago, Saint Lucia, Indonesia
8509386 Cable, PC RS-232, IBM
08H7968 Coax Adapter Cable for use with Multi-Platform Interface
13F9941 Line Cord, IBM, Australia
13F9980 Line Cord, IBM, Europe (EMEA)
13F9998 Line Cord, IBM, Denmark
14F0016 Line Cord, IBM, Pakistan, South Africa
14F0034 Line Cord, IBM, India, United Kingdom
14F0052 Line Cord, IBM, Switzerland
14F0070 Line Cord, IBM, Chile, Italy
14F0088 Line Cord, 9 Feet, Israel
14H5301 Line Cord, 6400, 12 Foot, United States, 125 Volt
14H5303 Line Cord, 6400, 8 Foot, Chicago
14H5305 Line Cord, 6400, 12 Foot, United States, 220 Volt
14H5309 Line Cord, 6400, Denmark
14H5311 Line Cord, 6400, Israel
14H5313 Line Cord, 6400, Chile, Italy
356
Appendix G
14H5315 Line Cord, 6400, Switzerland
14H5317 Line Cord, 6400, India, United Kingdom
14H5319 Line Cord, 6400, Europe (EMEA)
14H5321 Line Cord, 6400, Pakistan, South Africa
14H5323 Line Cord, 6400, Australia
14H5325 Line Cord, 6400, Japan
14H5335 Twinax Auto-Termination Cable (47 Inches)
14H5541 DP Adapter, 6400
21F4342 Cable, AS/400*, RS-232, IBM
38F8254 Twinax Auto-Termination Cable
57G7261 Power Cord, 6 Feet, Non-Lock, United States, Canada,110 Volt
58F2861 Conn, Cable, RISC System/6000*, IBM
63H7362 Cable, RISC System/6000
63H7364 Cable, AS/400, RS-232
63H7366 Cable, PC Parallel
63H7368 Cable, PC RS-232
63H7456 LAN Power Coupling
92F3176 Cable, PC Parallel, IBM
Part Number Description
357
H Part Numbers
Part Number Location Description
01P4611 page 274 Tractor Assembly, Power Stacker
01P4698 page 401 Fence, Wireform (Power Stacker)
01P4699 page 399 Field Kit, Power Stacker, Limit Switch
02N6214 page 313 Cable Assembly, Hammer Bank Power
02N8261 page 268 Connector Stiffening Clip
02N8315 page 284 Ethernet LAN PCBA, 100Base-T
02N8327 page 409 Field Kit, Power Stacker, PMD
02N8329 page 399 Pivot Arm Block
04H4779 page 252 Riser, Stacker Runner
08H7934 page 278 Platen Open Motor Pulley
08H7936 page 276 Platen Assembly
08H7954 page 258 Anti-Static Brush Kit
14H5154 page 278 Platen Open Motor Assembly
14H5159 page 278,
page 322
Hammer Bank Fan Assembly
14H5169 page 276 Platen Hardware Kit
14H5174 page 258 Platen/Paper Feed Cover Kit
14H5179 page 258 Paper Scale
14H5211 page 264 Clamp, Shaft, Receiving
14H5214 page 274 Tractor Shaft Kit
14H5217 page 274 Tractor Shaft Hardware Kit
14H5235 page 258 Shroud Assembly, Air (Shuttle Cover)
358
Appendix H
14H5271 page 258 Paper Guide Assembly (Models 004, 005, 008, 009, 010, 012,
014, C05)
14H5272 page 252 Chain Assembly Kit
14H5274 page 264 Shuttle Frame Assy (Models 004, 04P)
14H5275 page 264 Hammer Spring Kit (Models 004, 04P, 005, 05P)
14H5279 page 312 Cable Assy, Hammer Bank Logic
14H5280 page 276,
page 325
Platen Switch Kit
63H5133 page 278,
page 324
Paper Detector Switch Assembly (Standard)
14H5282 page 264,
page 326
Switch Assembly, Cover Open
14H5285 page 309 Cable Assy, Card Cage Fan
14H5286 page 311 Cable Assy, Exhaust Fan
14H5287 page 264,
page 284,
page 303
Centronics I/O Cable Assembly
14H5288 page 197 Housing, Connector Kit
14H5289 page 307 Cable Assy, AC-In, Power Supply (Part of AC Field Kit)
14H5289 page 308 Cable Assy, AC Power Input (Part of AC Field Kit)
14H5296 page 252 Spares Kit, Grommet
14H5299 page 254 Operator Panel Assembly (Cabinet)
14H5300 page 254,
page 256,
page 310
Cable Assembly, Operator Panel
14H5329 page 272,
page 314
Cable Assembly, MPU
14H5330 page 317 Cable Assembly, Shuttle Motor Drive
14H5490 page 220 Security Module, Graphics
14H5509 page 220 Security Module, Base
14H5512 page 264 Hammer Spring Kit (Models 008, 08P, 009, 09P)
14H5513 page 264 Hammer Spring Kit (Models 012, 014)
14H5516 page 264 Shuttle Frame Assy (Models 008, 08P)
14H5517 page 264 Shuttle Frame Assy (Model 012)
Part Number Location Description
359
14H5520 page 278 Paper Feed Motor
14H5521 page 278 Motor Assembly, Ribbon
14H5522 page 264,
page 304
Cable Assy, Centronics/Dataproducts Adapter
14H5525 page 236 Resistor Kit
14H5589 page 305 Cable Assy, +5V Remote Power
14H5567 page 250 Wireform Paper Path
14H5570 page 278,
page 324
Paper Detector Switch Assembly (Black Back Forms)
14H5571 page 262,
page 280
Circuit Breaker
14H5572 page 250 Hardware Kit
14H5592 page 194 Cable, Data, Coax/Twinax Multi-Platform Interface
14H5593 page 194 I/O Bracket Assembly, Coax/Twinax Multi-Platform Interface
14H5595 page 194 PROM, Coax/Twinax Multi-Platform Interface
14H5603 page 250 Logo, 6400
14H5643 page 264 CMX Controller Board, V5.0 (All models 004 and 04P. Models
008 and 012 with Serial Nos. 01AXXXX, 01BXXXX, and
01CXXXX.)
14H5644 page 264 Power Supply PCBA, (Models 004, 04P, 005, 05P, 008, 08P,
012)
24H8533 page 256 Input Tray (Optional)
24H8535 page 282 Adapter, Expansion Connector, 60-pin
24H8593 page 274 Paper Support
24H8647 page 264 CMX Controller Board, V5.5, 25 MHz (All models 005, 05P, and
08P. Models 008 and 012 with Ser. Nos. 01DXXXX, 01EXXXX,
and higher. All models 009 and 09P.)
24H8648 page 264 Shuttle Frame Assy (Models 005, 05P)
24H8766 page 18 6400 Operators Guide, English
24H8767 page 18 6400 Operators Guide, Spanish
24H8768 page 18 6400 Line Matrix Printer Setup Guide, French
24H8769 page 18 6400 Operators Guide, Italian
24H8770 page 18 6400 Operators Guide, German
Part Number Location Description
360
Appendix H
24H8771 page 18 6400 Operators Guide, Dutch
24H8772 page 18 6400 Operators Guide, Brazilian Portuguese
24H8773 page 18 6400 Line Matrix Printer Operators Guide, Japanese
24H8774 page 18 6400 Line Matrix Printer Setup Guide, English
24H8775 page 18 6400 Line Matrix Printer Setup Guide, Spanish
24H8776 page 18 6400 Operators Guide, French
24H8777 page 18 6400 Line Matrix Printer Setup Guide, Italian
24H8778 page 18 6400 Line Matrix Printer Setup Guide, German
24H8779 page 18 6400 Line Matrix Printer Setup Guide, Dutch
24H8780 page 18 6400 Line Matrix Printer Setup Guide, Brazilian Portuguese
24H8781 page 18 6400 Line Matrix Printer Setup Guide, Japanese
24H8828 page 268 Ribbon Mask, 500 (Models 050, P50)
24H8844 page 268 Ribbon Mask, 1000 (Models 010, 10P)
24H8858 page 268 Ribbon Mask, 1500 (Model 015)
24H8872 page 268 Hammer Bank Cover Assy, 500 (Models 050, P50)
24H8886 page 268 Hammer Bank Cover Assy, 1000 (Models 010, 10P)
24H8888 page 18 6400 ASCII Programmers Reference
24H8889 page 18 6400 IGP Users Manual
24H8890 page 18 6400 Code V Users Manual
24H8891 page 18 6400 CTA Programmers Reference
24H8892 page 18 6400 IPDS Programmers Reference
24H8893 page 18 Ethernet Interface Users Manual
24H8894 page 278,
page 315
Ribbon Guide Kit
24H8924 page 268 Hammer Bank Cover Assy, 1500 (Model 015)
24H8925 page 268 Shuttle Frame Assembly, 500 (Models 050, P50)
24H8927 page 268 Shuttle Frame Assembly, 1000 (Models 010, 10P)
24H8929 page 268 Shuttle Frame Assembly, 1500 (Model 015)
24H8931 page 268 Hammer Spring Field Kit, 500 (Models 050, P50)
24H8932 page 268 Hammer Spring Field Kit, 1000 (Models 010, 10P)
24H8933 page 268 Hammer Spring Field Kit, 1500 (Model 015)
Part Number Location Description
361
24H8959 page 250 Front Door Kit
24H8960 page 250 Rear Door Kit
24H8961 page 250 Top Cover Kit
24H8962 page 399 Rear Door, Extended, Power Stacker
24H8963 page 399 RE Ship Kit, Printer w/Power Stacker
24H8966 page 399 Paper Deflector (Power Stacker)
24H8968 page 399 Timing Belt (Power Stacker)
24H8969 page 399,
page 401
Motor (Power Stacker)
24H8970 page 399 Constant Force Spring (Power Stacker)
24H8971 page 399 Chain (Power Stacker)
24H8973 page 399 Cable (Power Stacker)
24H8974 page 399 Control Panel Assembly (Power Stacker)
24H8975 page 320 Power Cable, Power Stacker
24H8976 page 319 Logic Cable, Power Stacker
24H8978 page 401 Anti-Static Brush (Power Stacker)
24H8981 page 401 Extension Spring (Power Stacker)
24H8982 page 401 Idler Roller (Power Stacker)
24H8983 page 401 Paddle, Power Stacker
24H8985 page 403 Compression Spring (Power Stacker)
24H8988 page 403 Drive Roller (Power Stacker)
24H8989 page 405 LED, IR, T-1, 3/4 (Power Stacker)
24H8990 page 407,
page 409
Photodarlington, NPN, Rectifier (Power Stacker)
24H8991 page 409 LED, IR, Rectangular (Power Stacker)
24H8994 page 284 Ethernet LAN PCBA, 10Base2
24H8995 page 284 Ethernet LAN PCBA, 10Base-T
24H8996 page 399 Shaft, Lift (Power Stacker)
24H8997 page 401 Support Shaft (Power Stacker)
24H8999 page 405 Holder, LED, Round (Power Stacker)
Part Number Location Description
362
Appendix H
24H9000 page 407,
page 409
Holder, LED, Flat (Power Stacker)
24H9001 page 399 Pulley, Motor (Power Stacker)
24H9002 page 399 Pulley, Timing, Belt (Power Stacker)
24H9003 page 401 Collar Clamp (Power Stacker)
24H9004 page 399 Stacker Hardware Kit (Power Stacker)
24H9005 page 401 Shaft, Drive Roller (Power Stacker)
24H9006 page 401 Spacer, Drive Roller (Power Stacker)
24H9007 page 409 Sensor Assembly, PMD (Power Stacker)
24H9009 page 220 SIMM, Flash, Blank, 4 MB
24H9010 page 220 SIMM, DRAM, Blank, 8MB
24H9011 page 282 Expansion-CT PCBA
24H9625 page 264 Shuttle Frame Assy (Models 009, 09P)
24L5203 page 18 6400 Line Matrix Printers Operators Guide, Hanzi
24L5204 page 18 6400 -C05/-C5P Line Matrix Printers Setup Guide
24L5205 page 18 6400 -C05/-C5P Line Matrix Printers Programmers Reference-
LQ1600K
24L5207 page 268 Shuttle Frame Assembly, Models C05, C5P
24L5209 page 268 Hammer Spring Field Kit, Models C05, C5P
30H3981 page 252 Runner, Stacker
30H3985 page 272 Extension Spring
30H3986 page 250 Shipping Container Kit
30H4008 page 250 Wire Rope
30H4056 page 18 Print Server Users Guide
38F8254 page 306 Twinax Auto-Termination (Smart T)
38L0821 page 220 Security Module (Hanzi)
57G1421 page 278 Motor Pulley, Paper Feed
57G1440 page 278 Fan Assembly
57G1453 page 278,
page 324
Paper Detector Switch Assy
57G1460 page 274 Splined Shaft
Part Number Location Description
363
57G1466 page 274 Tractor Set
57G1468 page 258 Belt, Timing, 050P, 100 Teeth (Paper Feed)
57G1467 page 276 Belt, Timing, 312W, 87 Teeth (Platen Open)
57G1469 page 276 Ironer Assembly, Reverse Paper Feed
57G1476 page 272 Magnetic Pickup Assembly (MPU)
57G1479 page 278 Ribbon Hub Kit
57G1481 page 254 Dashpot Kit
57G1484 page 250 Hinge Plate, Bottom
57G1485 page 250 Caster, with Brake
57G1486 page 250 Caster, without Brake
57G1492 page 250 Window, Top Cover
57G1514 page 276 Platen Pulley, Driven
57G1521 page 274,
page 399
Ground Clip, Splined Shaft and/or Power Stacker
57G1571 page 276 Bracket, Ironer
57G1598 page 254 Operator Panel Overlay, English
57G1599 page 254 Operator Panel Overlay, Spanish
57G1600 page 254 Operator Panel Overlay, French
57G1601 page 254 Operator Panel Overlay, Italian
57G1602 page 254 Operator Panel Overlay, German
57G1603 page 254 Operator Panel Overlay, Dutch
57G1604 page 254 Operator Panel Overlay, Braz. Portuguese
57G7176 page 252 Stacker
57G7260 page 252 Power Cord, U.S. (See also Appendix G)
63H5116 page 260 Paper Path Assembly (Models 04P, 05P, 08P, 09P, C5P)
63H5118 page 256 Paper Basket
63H5119 page 256 Lid, Pedestal Model
63H5120 page 256 Top Cover, Complete (Pedestal Model)
63H5121 page 256 Hinge Lid Kit (Pedestal Model)
63H5122 page 256 Lid Accessory Kit (Pedestal Model)
63H5123 page 256 Shipping Container, Pedestal
Part Number Location Description
364
Appendix H
63H5124 page 256 Operator Panel (Pedestal)
63H5125 page 256 Bracket, Control Panel
63H7379 page 26 6400 Line Matrix Printer Configuration Utility Disk
63H7398 page 250 Top Cover Seal Kit
63H7464 page 316 Cable Assembly, Ribbon Motor, Extension
63H7478 page 276 Platen Lever Kit
63H7509 page 256 Caster, Pedestal
63H5117 page 256 Pedestal Kit
63H7510 page 250 Door Seal Kit
63H7518 page 264 Hmr Bank/Rbn Mask Cov Assy (Models 004, 04P, 005, 05P)
63H7519 page 264 Hmr Bank/Rbn Mask Cov Assy (Models 008, 08P, 009, 09P)
63H7520 page 264 Hmr Bank/Rbn Mask Cov Assy (Models 012, 014, C05, C5P)
83F2834 page 26 Torx T-10 Bit
90H3268 page 264 Power Supply PCBA (Models 050, P50, 009, 09P, 010, P10,
014, 015, C05, C5P)
90H3269 page 264 Shuttle Frame Assy (Model 014)
90H3271 page 268 CMX Controller Board, V5.5, 40 MHz (Models 050, P50, 010,
P10, 014, 015, C05, C5P)
93F7037 page 250 Hinge Plate, Top
S246-0149 page 18 6400 Coax/Twinax Multi-Platform Interface Option Installation
and Operation Guide
Part Number Location Description
365
I Noise Suppression Devices
Ferrite noise suppressors are installed in the printer to reduce radio frequency
interference (RFI) to and from electronic equipment located near the printer.
Two kinds of ferrite noise suppressors are used:
1. Shielding Bead: a cylindrical core, through and around which the control
panel cable assembly is wound. Two are required.
2. Ferrite Clamp: a noise suppression core in a hinged plastic case and
attached to the wall of the card cage with adhesive. The parallel I/O cable
assembly passes through this core.
Figure 58 shows how these devices are installed.
IMPORTANT
Duplicate the number of turns around the shielding beads when
installing or replacing the control panel cable. See Figure 58.
366
Appendix I
Figure 58. Ferrite Core Installation
NOTE: This core attaches
to the right rear card cage
wall.
Ferrite Core with Clamp
and Adhesive Backing
P/N 202049-001
Connector
P112
Connector
P110
Connector
P310
Connector
J203
NOTE: Two turns around
each bead.
Shielding Bead
P/N 141445-001
Control Panel Cable Assembly
Parallel I/O Cable Assembly
367
J SureStak Power Stacker
Contents
Introduction ..................................................................................... page 368
Stacker Operation ........................................................................... page 368
Component Locations............................................................... page 368
Stacker Control Panel ............................................................... page 370
Using The Power Stacker ......................................................... page 371
Loading And Starting The Power Stacker................................. page 372
Stacker Troubleshooting........................................................... page 374
Removing The Power Stacker ........................................................ page 375
Installing The Power Stacker .......................................................... page 380
Replacement Procedures:
Constant Force Spring.............................................................. page 391
Timing Belts.............................................................................. page 394
Illustrated Parts Breakdown ............................................................ page 398
368
Appendix J Introduction
Introduction
The SureStak Power Stacker is an option available for cabinet model printers.
Most of the stacker assembly is inside the cabinet, so usually you will have to
remove the stacker assembly from the printer in order to service it or replace
components.
The power paper stacker is designed to work with forms from 5 to 12 inches
(12.7 to 30.5 cm) long. Using longer or shorter paper can cause error
messages and unpredictable behavior of the stacker.
This appendix consists of three parts:
An overview of stacker operation.
Removal/installation instructions for the power stacker assembly and
components that require the most frequent replacement.
An illustrated parts breakdown (IPB) showing how the entire power
stacker unit is assembled. The IPB also lists the part numbers for
replaceable parts.
NOTE: Only replaceable parts have part numbers in the IPB. If you need to
replace a part for which no part number is shown, replace the entire
power stacker assembly.
Stacker Operation
The power stacker mechanically directs the paper from the printer to the
paper stack. It is mounted in the rear of the cabinet and has its own control
panel.
This section explains briefly how to use the power stacker.
Component Locations
Figure 59 shows the names and locations of the major components of the
paper stacker.
369
Legend:
1) Pinch Rollers
2) Paper Throat
3) Stacker Control Panel
4) Elevator Assembly
5) Motor Bracket
6) Wire Paper Tent
7) Paddle Shaft
8) Alignment Rod (2)
9) Bearing Bracket
10) Paper Length Indicator
Figure 59. Power Stacker Component Locations
1
2
3
5
6
7
8
9
10
4
370
Appendix J Stacker Operation
Stacker Control Panel
To gain access to the stacker control panel, open the rear door of the cabinet.
The control panel has two indicator lamps and four keys. (See Figure 60.)
Legend:
1) ON/OFF Indicator Lamp
2) On Line Indicator Lamp
3) On Line Key
4) Form Feed Key
5) Stacker Elevator Up Key
6) Stacker Elevator Down Key
Figure 60. Power Stacker Control Panel
ON/OFF Indicator LampLit when printer power is on. Unlit when
printer power is off.
ON LINE Indicator LampLit when printer is online to host computer
(READY). Unlit when printer is offline (NOT READY).
ON LINE KeyToggles the printer between the READY and NOT
READY operational states.
FORM FEED KeyMoves paper one form length as defined by the
currently active form length. This key is active only when the printer is in
the NOT READY state.
ELEVATOR UP KeyMoves the elevator to its highest position. This key
is active only when the printer is in the NOT READY state.
ELEVATOR DOWN KeyMoves the elevator to its lowest position. This
key is active only when the printer is in the NOT READY state.
$
$
1
2
3
4
5
6
371
Using The Power Stacker
1. Set the printer power switch to | (On).
2. Open the rear door of the cabinet.
3. On the stacker control panel, press ON LINE to take the printer to the
NOT READY state. (See Figure 60.)
4. Press the ELEVATOR UP key and wait for the stacker to reach the top of
its travel. (See Figure 60.)
5. Make sure the wire paper tent is in the base of the stacker with the
alignment rods against the vertical rails. (See Figure 61.)
Legend:
1) Vertical Rail
2) Paper Tent
3) Alignment Rod
Figure 61. Positioning the Paper Tent
6. Push or pull the paddle shaft toward the front or the rear of the printer and
set the paper length by aligning indicator notch on the bearing bracket
with the paper length indicator. (Length range: 5 to 12 inches.) (See
Figure 62.)
2
3
1
372
Appendix J Stacker Operation
Legend:
1) Paper Length Indicator
2) Paddle Shaft
3) Bearing Bracket
Figure 62. Setting Paper Length
Loading and Starting the Power Stacker
1. Press the FORM FEED key on the the stacker control panel and hand
feed the paper down into the paper throat. Continue to advance the paper
until it reaches the wire tent and there are 3 to 5 extra sheets in the
stacker. Make sure the paper passes through the throat of the paper
stacker. (See Figure 63.)
Figure 63. Paper Path in the Power Stacker
2. Stack the 3 to 5 sheets of paper on top of the wire paper tent, making sure
the paper lies with the natural fold.
$
$
1
2
3
373
3. Press the ON LINE key on the rear control panel or the Start key on the
front control panel to put the printer in the READY state. The stacker
elevator will descend to its lowest position. (See Figure 64.)
Figure 64. Power Stacker in Print Position
4. Check that the paper is still centered between the paper guides.
5. Close the cabinet rear door.
6. If necessary, set Top Of Form.
374
Appendix J Stacker Operation
Stacker Troubleshooting
The power stacker augments the paper feed system of the printer. The most
frequently occurring problems in the paper feed system are paper jams.
Because of the electromechanical nature of the system, other problems that
can occur are worn or poor electrical connections and cabling, worn or
defective feed motors, worn or damaged mechanical components, or
incorrect installation of the stacker assembly. Table 10 shows some of the
problems that may occur with the power stacker and the page where you can
find the troubleshooting procedure.
Table 10. Power Stacker Troubleshooting
Symptom Origin of Symptom Explanation Solution
Printer does not detect
presence of power
stacker
Reported by customer. Various causes possible. page 116
017 STACKER JAM
CHECK STACKER
Message on control
panel LCD.
Paper is bunching above the
elevator or the paper motion
detector is not working
properly.
page 68
018 STACKER FULL
CHECK STACKER
Message on control
panel LCD.
Status message: the power
paper stacker is full.
page 69
019 STACKER FAULT
CHECK STACKER
Message on control
panel LCD.
This message is triggered
when the elevator cannot
reach the top or bottom limit
switch before timing out.
page 70
Stacker chatters at
upper or lower limit
Reported by customer. Various causes possible. page 117
Stacker does not stack
properly
Reported by customer. Various causes possible. page 118
Stacker elevator does
not move
Reported by customer. Various causes possible. page 118
Stacker elevator moves
by itself
Reported by customer. Various causes possible. page 118
Stacker not operating Reported by customer. Same symptom as Printer
does not detect presence of
power stacker
page 116
375
Removing The Power Stacker
1. Set the printer power switch to O (off).
2. Unplug the power cord.
3. Unload paper from the stacker area. (Refer to the Setup Guide.)
4. Remove the paper tent. (See Figure 65.)
Legend:
1. Paper Tent
Figure 65. Removing the Paper Tent
5. Cut the tie wrap and remove the paper fence. (See Figure 66.)
Legend:
1. Paper Fence
2. Stacker Base
Figure 66. Removing the Paper Fence
1
1
2
376
Appendix J Removing The Power Stacker
6. Remove three screws and washers from the stacker control panel. (See
Figure 67.)
Legend:
1. Long Screw
2. Washer
3. Short Screw
Figure 67. Removing the Stacker Control Panel
7. Remove four cables from the stacker control panel, and remove the
stacker control panel. (See Figure 68.)
Legend:
1. Logic Cable (P104)
2. Power Cable
3. Frame Cable (P102)
4. Rail Cable (P107)
Figure 68. Removing Cables from the Stacker Control Panel
1
2
2
3
2
1
2
3
4
377
8. Remove the two 5/32 x 3/4 inch screws and washers securing the vertical
rails to the upper frame cross-member at the rear of the cabinet. (See
Figure 69.)
9. Raise the elevator assembly.
Legend:
1. Vertical Rail
2. Washer (2)
3. Screw, 5/32 x 3/4 inch (2)
4. Screw, 7/64 x 1/2 inch or Torx T-10 (2)
5. Washer (2) but no washers with Torx T-10 screws
6. Stacker Base
Figure 69. Preparing the Stacker for Removal
1
1
2
3
4
5
6
378
Appendix J Removing The Power Stacker
10. Loosen one turnDO NOT REMOVEthe Torx T-10 screws securing
the vertical rails to the stacker base. Each rail is secured by two screws.
(See Figure 70.)
Legend:
1. Screw, 6-32x1/4, Torx T-10: two at bottom of each rail
2. Vertical Rail
3. Stacker Base
Figure 70. Loosening the Lower Screws in the Vertical Rails
11. Remove the 7/64 x 1/2 inch screws and washers (or Torx T-10 screws)
securing the base plate to the cabinet floor. (See Figure 69.)
12. Lower the elevator assembly to its lowest position.
13. Slide the stacker assembly slightly to the right to clear the air exhaust
duct. Tilt the vertical rails toward the front of the printer until they clear the
upper frame cross-member. Slide the stacker assembly to rear and angle
it out of the cabinet, as shown in Figure 71.
2
3
1
379
Legend:
1. Upper Frame Cross-Member
2. Elevator Assembly
3. Stacker Base
4. Vertical Rail
Figure 71. Removing the Stacker Assembly
1
2
3
4
380
Appendix J Installing The Power Stacker
Installing The Power Stacker
NOTE: This procedure is for complete installation of the power stacker,
including cable assemblies and the stacker control panel.
1. Set the printer power switch to O (off).
2. Unplug the power cord.
3. Remove paper.
4. Loosen the three paper guide hold-down screws. Slide the paper guide to
the left and lift it off the card cage. (See Figure 72.)
Legend:
1. Paper Guide
2. Hold-Down Screw (3)
Figure 72. Remove the Paper Guide
1
2
381
5. Connect the power stacker logic cable P103 to connector J17 on the CMX
controller board. (See Figure 73.)
6. Disconnect the power supply cable from connector J101 on the CMX
controller board. (See Figure 73.)
7. Connect power supply cable connector P101 to the stacker power cable,
then connect the stacker power cable to connector J101 on the CMX
controller board. (See Figure 73.)
8. Route the stacker power cable and the stacker logic cable in front of the
CMX board and through the cutout beneath the card cage fan, as shown
in Figure 73.
Legend:
1. Power Supply Connector P101
2. CMX Board Connector J101
3. Connector P103
4. CMX Board Connector J17
5. Stacker Logic Cable
6. Stacker Power Cable
7. Cutout Beneath Card Cage Fan
Figure 73. Stacker Power and Logic Connections on the CMX Controller Board
1
2
3
4
5
6
7
382
Appendix J Installing The Power Stacker
ATTENTION
The paper stacker assembly mounts to the rear upper frame cross-
member and the cabinet floor. It is a snug fit. During installation, take
care to avoid scratching painted surfaces or damaging the stacker.
9. Loosen one turnDO NOT REMOVEthe Torx T-10 screws securing
the vertical rails to the stacker base. Each rail is secured by two screws.
(See Figure 74.)
Legend:
1. Screw, 6-32x1/4, Torx T-10: two at bottom of each rail
2. Vertical Rail
3. Stacker Base
Figure 74. Loosening the Lower Screws in the Vertical Rails
2
3
1
383
10. Position the elevator assembly at the bottom of the vertical rails. (See
Figure 75a.)
11. Position the stacker assembly slightly to the right in order to clear the air
exhaust duct, insert the vertical rails inside and under the upper frame
cross-member, then slowly swing the base of the stacker assembly into
the cabinet. (See Figure 75a.)
12. Work the stacker base rearward and engage the upper brackets of the
vertical rails under the upper frame cross-member. (See Figure 75b.)
13. Align the holes in the vertical rail brackets with the holes in the upper
frame cross-member. (See Figure 75c and Figure 76.)
384
Appendix J Installing The Power Stacker
Legend:
1. Upper Frame Cross-Member
2. Elevator Assembly
3. Stacker Base
4. Vertical Rail
Figure 75. Stacker Installation
1
2
3
4
a
b
c
385
14. Align the holes in the stacker base with the holes in the cabinet floor. (See
Figure 75c and Figure 76.)
15. Install finger tight the two 5/32 x 3/4 inch screws and washers securing
the vertical rails to the upper frame cross-member.
16. Install and tighten the four 7/64 x 1/2 inch screws and washers (or Torx T-
10 screws) securing the stacker base to the cabinet floor. (See Figure
76.)
17. Move the elevator assembly up and down on the vertical rails until it
travels smoothly with no binding.
18. Tighten the two 5/32 x 3/4 inch screws and washers securing the vertical
rails to the upper frame cross-member.
19. Move the elevator assembly up and down again to make sure it travels
smoothly with no binding.
20. Tighten the screws securing the vertical rails to the stacker base. Each
rail is secured by two screws. (See Figure 74.)
21. Move the elevator assembly up and down to make sure it travels
smoothly with no binding. If the elevator binds or catches anywhere along
its path of travel, slightly loosen the upper and lower rail screws and
repeat steps 17 through 20 until the elevator moves smoothly.
386
Appendix J Installing The Power Stacker
Legend:
1. Washer (2)
2. Screw, 5/32 x 3/4 inch (2)
3. Stacker Base
4. Screw, 7/64 x 1/2 inch or Torx T-10 (2)
5. Washer (2) but no washers with Torx T-10 screws
6. Vertical Rail
7. Upper Frame Cross-Member
Figure 76. Stacker Fasteners
1
2
3
6
NOTE: The stacker assembly is
exploded to show mounting screws
and locations.
7
4
5
387
22. Install the paper fence. (See Figure 77.)
Legend:
1. Paper Fence
2. Stacker Base
Figure 77. Paper Fence
1
2
388
Appendix J Installing The Power Stacker
23. Gather the rail cable, frame cable, logic cable, and power cable. Route
the cables outboard of the elevator assembly.
24. Connect the stacker cables to the rear of the stacker control panel
assembly, as shown in Figure 78.
Legend:
1. Logic Cable (P104)
2. Power Cable
3. Frame Cable (P102)
4. Rail Cable (P107)
Figure 78. Stacker Control Panel Cables
1
2
3
4
389
25. Position the stacker control panel as shown in Figure 79, and install the
mounting screws.
Legend:
1. Stacker Control Panel
2. Long Screw
3. Short Screw (2)
Figure 79. Installing the Stacker Control Panel
3
2
1
390
Appendix J Installing The Power Stacker
26. Bundle the stacker control panel cables in the wire harness clips located
under the card cage. (See Figure 80.) Tie wrap the cables so they do not
catch in the stacker mechanism as it moves up and down. Route the
stacker rail and frame cables so they move without snagging as the
elevator assembly moves up and down.
Legend:
1. Wire Saddle (2 places)
2. Cutout Beneath Card Cage Fan
3. Cable Bundle
Figure 80. Securing Stacker Cables
27. Install the paper path that you removed in step 4.
28. Install paper and test stacker operation. (Refer to the Setup Guide.)
1
2
3
391
Replacing The Constant Force Spring
1. Remove the stacker assembly from the printer. (See page 375.)
ATTENTION
In the next step, do not over-tighten the tie wraps or string. Tighten the
tie wraps or string just enough to hold the elevator up.
2. Raise the elevator assembly to its highest position and secure it to the
vertical rails using tie wraps or string. (See Figure 81.)
Legend:
1. Tie Wrap
2. Elevator Assembly
Figure 81. Securing the Elevator Assembly
1
2
1
392
Appendix J Replacing The Constant Force Spring
3. Remove the shoulder screw, washers, and spacer from the constant force
spring and drum. Let the spring coil itself up until it reaches the screw that
secures it to the vertical rail. (See Figure 82.)
4. Firmly gripping the spring and drum, remove the screw securing the
spring to the vertical rail. (See Figure 82.)
Legend:
1. Rail Screw
2. Washer
3. Constant Force Spring
4. Large Washer
5. Spacer
6. Drum
7. Shoulder Screw
Figure 82. Removing the Constant Force Spring
The constant force spring is a high tension spring. To avoid
pinching your fingers, coil the spring slowly and carefully.
Do not let the spring twist or crimp.
CAUTION
1
2
3
4
4
7
6
5
393
5. Lift the loose end of the constant force spring and let it curl up on the
outside of the remaining spring and drum. (See Figure 83.)
6. While holding the drum tightly, continue to curl the spring until it is
completely unwound from the drum. (See Figure 83.)
7. To install a new constant force spring, reverse the steps of this procedure.
Legend:
1. Spring
2. Drum
Figure 83. Removing the Constant Force Spring from the Drum
1
2
394
Appendix J Replacing The Timing Belts
Replacing The Timing Belts
1. Remove the stacker assembly from the printer. (See page 375.)
2. Raise the elevator assembly to its highest position and secure it to the
vertical rails using tie wraps or string. (See Figure 81, page 391.)
3. If you are removing the left timing belt, remove the shoulder screw from
the pulley at the bottom of the left vertical rail, and remove the pulley.
(See Figure 84.) Go to step 6.
4. If you are removing the right timing belt, remove the two metric Allen
screws that secure the timing belt motor to the right vertical rail. (See
Figure 84.) Go to step 5.
Legend:
1. Metric Allen Screw and Washer
2. Right Vertical Rail
3. Timing Belt Motor
4. Stacker Base
5. Bushing
6. Pulley
7. Shoulder Screw
8. Left Vertical Rail
Figure 84. Removing the Timing Belt Pulley and Motor
1
3
4
2
6
5
7
8
395
5. Loosen the two setscrews on the motor pulley and remove the pulley.
Unplug the motor cable, if necessary. (See Figure 85.) Go to step 6.
Legend:
1. Timing Belt Motor
2. Setscrew
3. Pulley
Figure 85. Removing the Timing Belt Motor Pulley
6. Remove the shoulder screw, washers, and spacer that secures the
constant force spring to the vertical rail. (See Figure 86.)
Legend:
1. Large Washer
2. Spacer
3. Constant Force Spring
4. Shoulder Screw
Figure 86. Releasing the Constant Force Spring
1
2
2
3
NOTE: Left is shown.
Right is the same.
1
1
2
3
4
396
Appendix J Replacing The Timing Belts
7. Remove two Allen screws from the belt clamp that secures the timing belt
to the stacker frame. (See Figure 87.)
Legend:
1. Allen Screw
2. Belt Clamp
Figure 87. Removing the Belt Clamps
1
2
2
1
397
8. Remove the timing belt by working it around the vertical rail and constant
force spring. (See Figure 88.)
Legend:
1. Timing Belt
Figure 88. Removing the Timing Belt
9. To install a timing belt, reverse the steps of this procedure.
NOTE: Left timing
belt is shown. Right is
the same.
1
398
Appendix J Illustrated Parts Breakdown
Illustrated Parts Breakdown
The Illustrated Parts Breakdown (IPB) consists of exploded drawings of the
power stacker assembly and subassemblies. Parts are listed next to each
drawing.
Only replaceable parts are assigned part numbers. If a part or assembly is
damaged but does not have a part number, replace the entire power stacker
assembly.
The IPB starts on the next page.
399
Figure 89. Stacker Assembly
$
14
30
35
10
12
20
9
37
12
5
8
8
13
15
25
7
11
20
9
12
10
6
7
38
38
38
See page 401.
40
400
Appendix J Illustrated Parts Breakdown
Item
No.
Part No. Description Notes
5 Ref Flanged Bearing Part of item 36
6 24H8966 Paper Deflector
7 Ref Clip-On Bearing Part of item 36
8 Ref Screw, Torx, 6-32 x .25 Part of item 36
9 Ref Screw, Shoulder, 10-32 Part of item 36
10 24H8968 Timing Belt
11 24H8996 Shaft, Lift
12 24H9002 Pulley, Timing Belt
13 24H9001 Pulley, Motor
14 57G1521 Clip, Grounding
15 24H8969 Motor
20 24H8970 Constant Force Spring
25 24H8971 Chain Mount chains outboard of
shafts
30 Ref Nylon Plug
35 24H8973 Cable
36 24H9004 Stacker Hardware Kit Kit not illustrated
37 Ref Screw, Shoulder, 8-32 Part of item 36
38 01P4699 Power Stacker Limit Switch Kit Replaces earlier limit
switches
40 170870-901 Limit Switch Assembly Replacement switch if item
38 is installed
24H8974 Control Panel Assembly Figure 78, page 388
Ref Rail Cable, Power Stacker See page 321
24H8975 Power Cable, Power Stacker See page 320
24H8976 Logic Cable, Power Stacker See page 319
Ref Frame Cable, Power Stacker See page 318
24H8962 Rear Door, Extended, Power Stacker Not illustrated
24H8963 RE Ship Kit, Printer w/Power Stacker Not illustrated
401
Figure 90. Stacker Detail: Motors, Rollers, and Paddles
$
%
(
&
'
'
47
48
40
46
45
50
46
45
49
51
15
15
53
15
45
46
45
46
50
55
60
55
50
65
52
53
54
54
52
65
From page 399.
See page 405.
See page 403.
See page 407.
See page 407.
See page
409.
402
Appendix J Illustrated Parts Breakdown
Item
No.
Part No. Description Notes
15 24H8969 Motor
36 24H9004 Stacker Hardware Kit Kit not illustrated
40 24H8978 Anti-Static Brush
45 Ref Shear Grommet Part of item 36
46 Ref Cap Nut Part of item 36
47 24H9005 Shaft, Drive Roller
48 24H9006 Spacer, Drive Roller
49 Ref Bearing, Flanged Part of item 36
50 Ref Bearing Part of item 36
51 24H9003 Collar Clamp
52 Ref Collar, Setscrew Part of item 36
53 24H8997 Support Shaft
54 01P4698 Fence, Wireform
55 24H8981 Extension Spring
60 24H8982 Idler Roller Five on early models
65 24H8983 Paddle, Power Stacker
403
Figure 91. Stacker Detail: Rollers
%
75
80
85
90
85
80
From page 401.
404
Appendix J Illustrated Parts Breakdown
Item
No.
Part No. Description Notes
36 24H9004 Stacker Hardware Kit Kit not illustrated
75 24H8985 Compression Spring On left end of shaft on early
models
80 Ref Friction Washer Part of item 36
85 Ref Flanged Bushing Part of item 36
90 24H8988 Drive Roller Five on early models
405
Figure 92. Stacker Detail: Motor Bracket
&
95
95
96
96
100
Connector
Flat Side
Flag
Key
From page 401.
406
Appendix J Illustrated Parts Breakdown
Item
No.
Part No. Description Notes
36 24H9004 Stacker Hardware Kit Kit not illustrated
95 Ref Clip-On Bearing Part of item 36
96 24H8999 Holder, LED, Round
100 24H8989 LED, IR, T-1, 3/4
407
Figure 93. Stacker Detail: Elevator Bracket
95
97
Connector
Flag
Key
'
95
Nib
105
From page 401.
408
Appendix J Illustrated Parts Breakdown
Item
No.
Part No. Description Notes
36 24H9004 Stacker Hardware Kit Kit not illustrated
95 Ref Clip-On Bearing Part of item 36
97 24H9000 Holder, LED, Flat
105 24H8990 Photodarlington, NPN, Rectifier
409
Figure 94. Stacker Detail: Paper Motion Detector
P5STK01Z
T5stk01x
105
Connector
Flag
Key
Nib
105
(
Rotated 180 Degrees
97
110
97
107
107
116
115
107
108
106
107
From page 401.
410
Appendix J Illustrated Parts Breakdown
Item
No.
Part No. Description Notes
36 24H9004 Stacker Hardware Kit Kit not illustrated
97 24H9000 Holder, LED, Flat
105 24H8990 Photodarlington, NPN, Rectifier
106 Ref Retaining Ring, External, 0.093 inch Part of item 115
107 Ref Screw, Panhead, Type B, 2 x 3/16 Part of item 36
108 Ref Shaft, Paper Detector Switch, Long Part of item 115
110 24H8991 LED, IR, Rectangular
115 02N8327 Field Kit, Power Stacker, PMD
116 Ref Spring, Torsion Part of item 115
411
Index
Numerics
001 END OF FORMS / LOAD FORMS, 62
002 FORMS JAMMED / CLEAR JAM AND
RELOAD FORMS, 63
003 FORMS EJECTED / PRESS EJECT/
RESTORE, 64
006 HOST SYSTEM REQUEST ATTENTION, 64
007 FM HEADER ERROR, 64
008 HOLD PRINT TIMEOUT / PRESS START, 64
009 INVALID KEY PRESS, 64
010 PARAMETER ERROR, 65
011 SCS COMMAND ERROR, 65
012 STRUCTURED FIELD ERROR, 65
013 ACTIVATE LOST, 66
014 INVALID ACTIVATE, 66
015 COMMUNICATIONS CHECK / CHECK
CABLE, 67
016 INVALID COMMAND, 67
017 STACKER JAM / CHECK STACKER, 68
018 STACKER FULL / CHECK STACKER, 69
019 STACKER FAULT / CHECK STACKER, 70
021 RECEIVE BUFFER OVERRUN / VERIFY
CONFIGURATION, 71
022 UNIT ADDRESS NOT RECEIVED / CHECK
PRINTER ADDRESS, 71
024 SERIAL LINE PARITY ERROR / VERIFY
CONFIGURATION, 71
025 SERIAL FRAMING ERROR / VERIFY
CONFIGURATION, 72
026 EXHAUST FAN FAULT, 81
026 HEX DUMP MODE, 72
027 COMMUNICATIONS CHECK / CALL SYSTEM
OPERATOR, 72
028 COMMUNICATIONS CHECK / CALL SYSTEM
OPERATOR, 72
029 8344 DIAGNOSTIC TEST FAILED, 72
031 END OF FORMS TIMEOUT / LOAD FORMS,
73
032 FORMS JAMMED TIMEOUT / CLEAR JAM
AND RELOAD FORMS, 74
04 VIEW FORMS / PRESS VIEW KEY, 64
041 BUFFER OVERFLOW, 75
042 CUSTOM SET DOES NOT EXIST / SAVE
FIRST, 75
043 CUSTOM SET ALREADY EXISTS / DELETE
EXISTING SET FIRST, 75
044 EC FIRMWARE/HARDWARE ERROR, 76
046 EC STOPPED AT STATE, 76
057 CLOSE PLATEN, 77
058 SHUTTLE JAM / SEE USERS GUIDE, 78
059 CANCEL PRINT ACTIVE, 79
060 PRINTER HOT, 80
065 HAMMER BANK FAN FAULT, 82
069 DATA CLEARED, 82
080 POWER SUPPLY HOT, 83
081 POWER SUPPLY VOLTAGE FAILURE, 84
082 POWER SUPPLY 8.5V FAILED, 84
083 INTAKE FAN FAULT, 84
084 POWER SUPPLY 48V FAILED, 85
085 CONTROLLER VOLTAGE, 85
086 CONTROLLER 15V, 86
087 PLATEN OPEN TIMEOUT / CLOSE PLATEN,
87
088 CONTROLLER 23.5V, 88
089 RIBBON STALL, 89
090 SHUTTLE COVER OPEN / CLOSE SHUTTLE
COVER, 90
092 RIBBON DRIVER CIRCUIT, 90
412
101 UPPER DRIVER SHORT, 91
102 LOWER DRIVER SHORT, 91
105 HAMMER COIL OPEN, 91
107 HAMMER COIL HOT, 92
110 STACK OVERFLOW / SEE USERS GUIDE,
93
111 STACK UNDERFLOW / SEE USERS GUIDE,
93
112 UNDEFINED OPCODE / SEE USERS GUIDE,
93
113 PROTECTED INSTRUCTION / SEE USERS
GUIDE, 93
114 ILLEGAL OPERAND ACCESS / SEE USERS
GUIDE, 93
115 ILLEGAL INSTRUCTION ACCESS / SEE
USERS GUIDE, 93
116 ILLEGAL EXTERNAL BUS ACCESS / SEE
USERS GUIDE, 94
117 A TO D OVERRUN / SEE USERS GUIDE, 94
118 UNDEFINED INTERRUPT / SEE USERS
GUIDE, 94
119 TCB CORRUPTED / SEE USERS GUIDE, 94
120 ACCESS NULL POINTER / SEE USERS
GUIDE, 94
121 PAPER NOT AT SPEED / SEE USERS
GUIDE, 94
122 PAPER NOT SCHEDULED / SEE USERS
GUIDE, 95
123 PAPER BUSY TOO LONG / SEE USERS
GUIDE, 95
124 PAPER FIFO OVERFLOW / SEE USERS
GUIDE, 96
125 PAPER FIFO UNDERFLOW / SEE USERS
GUIDE, 96
126 PAPER FEED BAD TABLE / SEE USERS
GUIDE, 97
127 PAPER FEED ILLEGAL STATE / SEE USERS
GUIDE, 97
128 PAPER FEED INVALID COMMAND / SEE
USERS GUIDE, 97
129 PAPER FEED INVALID PARAMETER / SEE
USERS GUIDE, 97
130 PAPER FEED PARTLY ENERGIZED / SEE
USERS GUIDE, 97
131 PAPER FEED INTERRUPT / SEE USERS
GUIDE, 98
132 RIBBON INVALID COMMAND / SEE USERS
GUIDE, 98
133 RIBBON INVALID STATE / SEE USERS
GUIDE, 98
134 PLATEN INVALID COMMAND / SEE USERS
GUIDE, 98
135 PLATEN INVALID STATE / SEE USERS
GUIDE, 98
136 PLATEN INVALID PARAMETER / SEE
USERS GUIDE, 98
137 SHUTTLE INVALID COMMAND / SEE
USERS GUIDE, 99
138 SHUTTLE INVALID PARAMETER / SEE
USERS GUIDE, 99
139 SHUTTLE OVERSPEED / SEE USERS
GUIDE, 99
990 MACHINE CHECK, 99
998 NON-VOLATILE MEMORY FAILED, 99
A
A97 GRAPHIC CHECK ERROR / PRESS STOP
THEN START, 99
Abbreviations, 347
About the printer, 13
Acronyms, 347
Adapters and Cords, 355
Adjustments, 151
coil temperature, 181
end of forms distance, 169
Ethernet initialization, 183
hammer phasing, 173
loading flash memory, 176
paper drive motor pulley alignment, 158
paper feed timing belt tension, 154
paper scale, 160
platen gap, 162
platen open belt, 156
platen open motor pulley alignment, 164
ribbon guide, 166
set shuttle speed, 182
413
software upgrades, 176
splined shaft skew adjustment, 168
ASCII Character Set chart, 142
Attention condition, 61
B
Belt
paper feed timing, replacement, 188
paper feed timing, tension adjustment, 154
platen open, replacement, 189
platen open, tension adjustment, 156
Block diagram
operator panel, 44
Boards
layouts, connections, and pinouts, 287
BOOT DIAGNOSTICS, 100
C
Cabinet, doors, reversing, 206
Cable assembly
interconnections, 287
part numbers, 287
routing diagrams, 287
shell and cable replacement, 195, 198
Cable connectors and shells
replacement, 195, 198
Call, start of, 60
Card cage
fan assembly, replacement, 209
CE tests, 134
Character Set
U.S. ASCII, 142
Checks, service
customers power source, 345
power on/off verification, 345
print interlock, 345
print mechanism, 343
printer power cable, 345
Circuit board
replacement
controller, 190
power supply, 192
Circuit breaker
replacement, 193
Cleaning the printer, 29
CLEARING PROGRAM FROM FLASH, 100, 178,
180
CMX controller board See Controller board, 45
Coax/twinax expansion board
replacement, 215
Coax/twinax multi-platform interface, replacement,
194
Coil temperature adjustment, 181
Communications failures, 131
Configuration, 27
Control panel See Operator panel, 227
Controller board
principles of operation, 45
Controller circuit board
replacement, 190
Controls and indicators, 20
mechanical, all models, 24
printing conventions, 18
Conversion, metric measurement, 337
Cords and Adapters, 355
Cores, Noise Suppression, 365
Cover assembly
hammer bank / ribbon mask, replacement, 200
shuttle, 203
top, pedestal model, 204
Customer Engineer (CE) tests, 134
Cycle power, 145
D
Dashpot, replacement, 205
Data controller (DC), 47
DC (Data Controller, CMX board), 47
Diagnostic menus
boot, 137
Diagnostic self-tests
customer engineer (CE), 134
operator print, 132
printer information menu, 143
Diagnostics
10/100Base-T, 54
DIAGNOSTICS PASSED, 178
Diagrams
414
cable routing, 287
ground path, 341
interconnection and cables, 287
Dimensions
printer, 329
Dipswitches
10/100Base-T, 55
Display (LCD)
list of messages, 62
Display messages, list of, 62
Display messages, printing conventions, 18
Documents related to this manual, 18
Doors, cabinet, reversing, 206
DRIVER CIRCUIT BAD, 100
Duty cycle, 336
E
EC (Engine Controller, CMX board), 49
Electrical characteristics, 330
End of Forms Adjust
procedure, 169
ENERGY SAVER ACTIVE, 100
Energy Star compliance, 329
Engine controller (EC), 49
Environmental characteristics, 329
ERROR
DC PROGRAM NOT VALID, 178
DRAM AT ADDRESS, 100
DRAM AT ADDRESS XXXXXXXX, 178
DRAM NOT DETECTED, 100
EC PROGRAM NOT VALID, 178
EC STOPPED AT STATE XXXX, 178
FLASH DID NOT PROGRAM, 101
FLASH NOT DETECTED, 179
NO DRAM DETECTED, 179
NVRAM FAILURE, 179
PROGRAM NEEDS MORE DRAM, 179
PROGRAM NEEDS MORE FLASH, 179
PROGRAM NOT COMPATIBLE, 179
PROGRAM NOT VALID, 101, 179
SECURITY PAL NOT DETECTED, 101, 179
SHORT AT ADDRESS XXXX, 101, 179
WRITING TO FLASH, 178, 180
Error log
clear, 135
print, 132
Error messages, 61
Error messages, list of, 62
ERROR OCCURRED / FLUSHING QUEUES*,
101, 180
ETHERNET ADAPTER BEING INITIALIZED, 101
ETHERNET DETECTED, 102
Ethernet interface assemblies
initialization procedure, 183
LEDs and DIP switches, 52
replacement, 207
F
Fan assembly
card cage, replacement, 209
hammer bank, replacement, 208, 210
Fault messages, 61
list of, 62
Fault symptoms
not from messages, 110
Flash memory
pre-written, part numbers for early models, 219
pre-written, part numbers for later models, 219
Flash memory, loading, 176
Flash messages
CLEARING PROGRAM FROM FLASH, 178
DIAGNOSTICS PASSED, 178
ERROR
DC PROGRAM NOT VALID, 178
DRAM AT ADDRESS XXXXXXXX, 178
EC PROGRAM NOT VALID, 178
EC STOPPED AT STATE XXXX, 178
FLASH NOT DETECTED, 179
NO DRAM DETECTED, 179
NVRAM FAILURE, 179
PROGRAM NEEDS MORE DRAM, 179
PROGRAM NEEDS MORE FLASH, 179
PROGRAM NOT COMPATIBLE, 179
PROGRAM NOT VALID, 179
SECURITY PAL NOT DETECTED, 179
SHORT AT ADDRESS XXXX, 179
415
WRITING TO FLASH, 178, 180
WRONG CHECKSUM, 180
ERROR OCCURRED / FLUSHING QUEUES*,
180
LOADING PROGRAM FROM PORT XX%, 180
LOADING PROGRAM INTO FLASH, 180
RESETTING... PLEASE WAIT, 180
RESTORING BOOT CODE, 180
SECURITY CODE VIOLATION, 180
SENDING PROGRAM TO EC PROCESSOR,
180
TABLE MISMATCH / DOWNLOAD AGAIN,
180
FM HEADER ERROR, 102
FREEFORM OFF, 102
OFF HOLD KEY @ PWRUP, 102
G
Gap, adjustment
magnetic pick-up (MPU), 216
platen, 162
Ground path diagram, 341
H
Hammer
phasing adjustment, 173
spring assembly, replacement, 211
Hammer bank
cover assembly, replacement, 200
fan assembly, replacement, 208, 210
wiring diagram, 287
HAMMER BANK NOT INSTALLED, 102
HAMMER COIL BAD #, #, #, #, ... etc., 103
Hammer phasing adjustment, 173
Hanzi models, 14
Hard reset, 145
Hex code printout, 140
Hub, ribbon, replacement, 238
I
IBM Coax/twinax expansion board, replacement,
215
Illustrations, replacement procedures, 249
Indicators
10/100Base-T, 54
Information menu, printer, 143
Inspection, safety, guide, 341
Installation, 27
Installed memory, 143
Interface
coax/twinax multi-platform, replacement, 194
specifications, 336
INTERRUPT UNUSED VECTOR 00, 103
K
Keys, operator panel
cabinet models, 20
pedestal models, 22
L
Labels, specifications, 328
LAN interface assemblies, replacement, 207
Levers and knobs, 24
Line matrix printing explained, 35
LOADING PROGRAM FROM PORT XX%, 103,
180
LOADING PROGRAM INTO FLASH, 103
M
Magnetic pick-up assembly
gap adjustment, 216
replacement, 216
Maintenance
adjustments, 151
cleaning the printer, 29
overview, 13
preventive, 29
Manual
how to use, 16
notes and notices, 17
printing conventions, 18
related documents, 18
Mechanical controls and indicators, 24
Memory modules, location and replacement, 217
Memory, flash
loading software, 176
Memory, installed, 143
Menus
416
boot diagnostics, 137
Customer Engineer (CE) tests, 134
Messages
list of, 62
Metric measurement, conversion tables, 337
Mnemonics, 347
Mode
auto reset, 55
run, 55
Models, printer, 13, 15
Module, security, location, 220
Motor
paper feed drive, replacement, 221
platen open, replacement, 223
ribbon drive, replacement, 225
MPU See Magnetic pick-up assembly, 216
Multi-platform interface, replacement, 194
N
Network print server, replacement, 226
Noise Suppression, 365
NOT READY, 103
Notes and notices, 17
Numbers
replacement parts, 357
O
Operation, principles of, 35
OPERATOR MENU /, 103
OPERATOR MENU LOCKED, 103
OPERATOR MENU UNLOCKED, 104
Operator panel
block diagram, 44
replacement
cabinet model, 227
pedestal model, 228
P
P05 DIAGNOSTIC TEST PASSED, 104
P17 SECURITY VIOLATION, 104
P60 ERROR
DRAM AT ADDRESS, 104
P61 ERROR
FLASH NOT DETECTED, 104
P62 ERROR
DC PROGRAM NOT VALID, 104
P63 ERROR
PROGRAM NOT COMPATIBLE, 105
P64 ERROR
CHECKSUM WRONG, 105
P65 ERROR
PROGRAM NEEDS MORE FLASH, 105
P66 ERROR
PROGRAM NEEDS MORE DRAM, 105
P67 ERROR
WRITING TO FLASH, 105
P68 ERROR
EC PROGRAM NOT VALID, 106
P69 ERROR
EC STOPPED AT STATE XXXX, 106
PA1 SELECTED, 104
PA2 SELECTED, 104
Panel, control See Operator panel, 227
Paper
detector switch assembly, replacement, 246
drive motor pulley alignment, 158
feed drive motor, replacement, 221
feed timing belt replacement, 188
feed timing belt tension adjustment, 154
ironer, replacement, 230
scale adjustment, 160
specifications, 328
stacker, power, 367
tractor (L/R), replacement, 248
Paper detector switch
replacement, 246
Paper guide assembly, removal, 229
Parts
illustrations, 249
replacement part numbers, 357
replacement procedures, 186
Phasing adjustment, 173
Pinouts, 287
Platen
gap adjustment, 162
interlock switch assembly, replacement, 247
platen open belt adjustment, 156
417
platen open motor, replacement, 223
Platen replacement, 231
PLEASE WAIT ... RESET IN PROGRESS, 106
Power
cycle, how to, 145
on/off verification, 345
start up sequence, 146
Power consumption, 330
Power on sequence, 146
Power Paper Stacker
component locations, 368
loading and starting, 372
setting up, 371
Power supply
circuit board replacement, 192
Power supply board
principles of operation, 57
Poweron time, 143
Principles of operation, 35
Print server, network, 226
Print strokes, 143
Printer
adjustments, 151
boot diagnostics menu, 137
cleaning, 29
configuration, 27
description, 13
dimensions, 329
duty cycle, 336
installation, 27
logical control of, 43
maintenance overview, 13
models, 13
evolution, 15
Hanzi, 14
how to identify, 15
power paper stacker, 367
principles of operation, 35
reset, 145
self-tests
customer engineer (CE), 134
operator print, 132
specifications, 327
troubleshooting, 59
Printer information menu
11 inch pages, 143
installed memory, 143
poweron time, 143
print strokes, 143
printing time, 143
Printing
conventions is this manual, 18
line matrix printing explained, 35
problems, 59
Printing time, 143
Printouts
hex code, 140
Procedures
adjustment, 151
cleaning, 29
safety inspection, 341
R
READY, 106
Replacement
card cage fan assembly, 209
circuit breaker, 193
Coax/twinax expansion board, 215
Coax/twinax multi-platform interface, 194
connector shells, 195
connector stiffening clips, 198
controller circuit board, 190
cover assembly, shuttle, 203
cover assembly, top, pedestal model, 204
cover open switch assembly, 245
dashpot, 205
doors, cabinet, reversing, 206
Ethernet interface assemblies, 207
extension spring, 244
hammer bank /ribbon mask cover assembly,
200
hammer bank fan assembly, 208, 210
hammer spring, 211
IBM Coax/twinax expansion board, 215
LAN interface assemblies, 207
magnetic pick-up assembly, 216
418
memory modules, 217
multi-platform interface, 194
network print server, 226
operator panel assembly
cabinet model, 227
pedestal model, 228
paper detector switch assembly, 246
paper feed drive motor, 221
paper feed timing belt, 188
paper guide assembly, 229
paper ironer, 230
platen, 231
platen interlock switch assembly, 247
platen open belt, 189
platen open motor, 223
power supply circuit board, 192
print server, network, 226
resistors, terminating, 235
ribbon drive motor, 225
ribbon guide assembly (L/R), 237
ribbon hub, 238
shuttle frame assembly, 242
splined shaft, 239
support shaft, 241
tractor (L/R), 248
Reset Mode, 55
Reset, soft vs. hard, 145
RESETTING ... PLEASE WAIT, 106
RESETTING... PLEASE WAIT, 180
Resistors, terminating
location of, 236
RESTORING BOOT CODE, 107
RESTORING BOOT CODE (message), 180
Ribbon
drive motor, replacement, 225
guide assembly (L/R), replacement, 237
guide assembly, alignment, 166
hub, replacement, 238
mask, replacement, 200
specifications, 327
RIBBON OUT OF INK / CHANGE RIBBON, 107
Run Mode, 55
S
Safety
inspection guide, 341
notices, defined, 17
SECURITY CODE VIOLATION, 180
Security module, location, 220
Self Test
10/100Base-T, 54
Self-tests
customer engineer (CE), 134
operator print, 132
printer information menu, 143
SENDING PROGRAM TO EC PROCESSOR, 107,
180
SERVICE /, 107
Service checks
customers power source, 345
power on/off verification, 345
print interlock, 345
print mechanism, 343
printer power cable, 345
Set shuttle speed, 182
Shaft
splined, replacement, 239
splined, skew adjustment, 168
support, replacement, 241
Shuttle
cover assembly, replacement, 203
frame assembly, replacement, 242
speed setting, 182
Signal mnemonics, 347
SIMMs, location and replacement, 217
Soft reset, 145
Software
loading into flash memory, 176
SOFTWARE ERROR* / Cycle power, 107
Specifications
dimensions, printer, 329
duty cycle, 336
electrical, 330
environmental, 329
interfaces, 336
419
paper, 328
ribbon, 327
Speed
shuttle, set, 182
Splined shaft
replacement, 239
skew adjustment, 168
Spring
extension, replacement, 244
Stacker, power, 367
control panel, 370
installation, 380, 398
loading and starting, 372
operation, 368
replacing
constant force spring, 391
timing belts, 394
Start of call, 60
Start up sequence, 146
Supplies, tools, and test equipment, 26
Support shaft
replacement, 241
Switch
cover open switch assembly, replacement, 245
paper detector switch assembly, replacement,
246
platen interlock switch assembly, replacement,
247
power, replacement, 193
Symptom list, troubleshooting, 110
Symptoms
from LCD messages, 62
not from messages, 110
T
TABLE MISMATCH / DOWNLOAD AGAIN, 107,
180
Temperature, coil, adjustment, 181
Tension adjustment
paper feed timing belt, 154
platen open belt, 156
Terminating resistors
location of, 236
replacement, 235
Test
equipment, tools, and supplies, 26
TESTING HARDWARE / PLEASE WAIT, 107
Tests
boot diagnostics menu, 137
customer engineer (CE), 134
print, operator, 132
printer information menu, 143
Time
poweron, 143
printing, 143
Tools, test equipment, and supplies, 26
TOP OF FORM SET, 107
Torque
conversion to or from metric, 337
table, 339
Tractor
replacement, 248
Troubleshooting, 59
aids, 59
communications failures, 131
fault messages, 61
symptoms not indicated by messages, 62
U
Unit check condition, 61
Upgrading software, 176
W
WAITING FOR ETHERNET ADAPTER, 108
WAITING FOR PROGRAM DOWNLOAD, 108
Wiring diagrams, 287
420
Preliminary 1
Copyright IBM Corp., 1995, 2000
S246-0117-08
164636-001B
*07S246011708*
01P4612
*0401P4612*